Device and method for transporting sample containers within a diagnostic laboratory system

Abstract

A method of operating a diagnostic laboratory system for analyzing biological samples is provided. The method includes providing a track within the diagnostic laboratory system, the track extending between a plurality of instruments, and providing a plurality of sample carriers movable on the track; and modeling the track in software as a plurality of blocks, each block including a movement pattern limiting the number of sample carriers within the block and indicating permitted directions in which the sample carriers may move into and out of the block. The method includes communicating availability in a first block and then, in response to the communicated availability, moving the sample carrier from a second adjacent block to the first block. Other methods and systems are also disclosed.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 384,061, filed November 16, 2022, entitled "DEVICES AND METHODS FOR TRANSPORTING SAMPLE CONTAINERS IN DIAGNOSTIC LABORATORY SYSTEMS," the disclosure of which is incorporated herein by reference in its entirety for all purposes.

[0002] The present disclosure relates to devices and methods for transporting sample containers within a diagnostic laboratory system. [Background technology]

[0003] Diagnostic laboratory systems may perform clinical chemistry or analysis to identify analytes or other components in biological samples such as serum, plasma, urine, interstitial fluid, cerebrospinal fluid, etc. Samples may be received in sample containers and / or transported throughout the laboratory system in sample containers. Many diagnostic laboratory systems process large volumes of sample containers and the samples contained therein. Summary of the Invention [Problem to be solved by the invention]

[0004] Sample processing involves transporting sample containers on trucks throughout a diagnostic laboratory system. As the size of a diagnostic laboratory system increases, the complexity of each truck also increases. The complexity of the transport programs that generate instructions for transporting the sample containers also increases, which can slow sample transport or cause problems such as sample container collisions. Therefore, there is a need for a system and method that provides simplified transport of sample containers throughout a diagnostic laboratory system. [Means for solving the problem]

[0005] According to a first aspect, there is provided a method of operating a diagnostic laboratory system for analyzing biological samples, the method comprising: providing a track within the diagnostic laboratory system, the track extending between a plurality of instruments; providing a plurality of sample carriers movable on the track; modeling in software via a computer the track as a plurality of blocks, each block including a movement pattern indicating an allowed direction for the sample carrier to move into or out of the block; sensing, via a track sensor, the vacancy of a first block; and, in response to sensing the vacancy of the first block, moving the sample carrier from a second block adjacent to the first block into the first block.

[0006] In another aspect, a diagnostic laboratory system for analyzing biological samples is provided, the system including at least one instrument for preparing or testing the biological sample; a track configured to transport sample containers configured to hold the biological sample to be analyzed to and from the at least one instrument; and a computer configured to: model in software the track as a plurality of blocks, each block including a movement pattern indicating one or more allowed directions in which a sample carrier may move into or out of the block; identify at least one test to be performed on the biological sample by the at least one instrument; and determine a path along the track to the at least one instrument, the path including at least a first block and a second block adjacent to the first block. The system further includes a first segment controller associated with the first block and a second segment controller associated with the second block and in communication with the first segment controller; the first segment controller operates to communicate that the first block is vacant; and the second segment controller operates to facilitate movement of the sample container from the second block to the first block in response to receiving communication from the first segment controller that the first block is vacant.

[0007] In a further aspect, a method for moving a sample carrier within a diagnostic laboratory system for analyzing biological samples is provided, the method including: providing a track within the diagnostic laboratory system, the track extending between a plurality of instruments; providing a sample carrier containing a biological sample, the sample carrier being movable on the track; modeling the track in software via a computer as a plurality of blocks, each block including a motion pattern indicating one or more allowed directions in which the sample carrier may move into or out of the block, each block configured to have only one sample carrier at a time; providing a plurality of segment controllers configured to control transport of the sample carrier through the plurality of blocks, the motion pattern of each block being defined by the segment controller associated with the block; identifying at least one test to be performed on the biological sample using at least one instrument; generating a routing plan for the sample carrier using a routing program, the routing plan including a list of blocks through which the sample carrier will travel to reach the at least one instrument; generating a queue of block commands for each block in the list of blocks; and moving the sample carrier through the blocks in the list of blocks based on the queue of block commands for each block in the list of blocks.

[0008] Further aspects, configurations, and advantages of the present disclosure will be readily apparent from the following description and illustration of several exemplary embodiments, including the best mode contemplated for carrying out the disclosure. The present disclosure is also capable of other and different embodiments, and its several details can be modified in various respects, all without departing from the scope of the present disclosure.

[0009] The drawings described below are provided for illustrative purposes and are not necessarily drawn to scale. Accordingly, the drawings and descriptions should be regarded as illustrative in nature, and not restrictive. The drawings are not intended to limit the scope of the present disclosure in any way. [Brief explanation of the drawings]

[0010] [Figure 1A] FIG. 1 is a diagram of a diagnostic laboratory system according to one or more embodiments. [Figure 1B] FIG. 1B illustrates an expanded portion of the track of the diagnostic laboratory system of FIG. 1A in accordance with one or more embodiments. [Figure 1C] FIG. 1C illustrates an enlarged portion of the track of FIG. 1B showing individual blocks and transport components, according to one or more embodiments. [Figure 1D] 1B is an isometric close-up view of a portion of the track of FIG. 1A including two sample carriers holding sample vessels, the sample vessels containing samples, and the sample carriers being independently movable, according to one or more embodiments. [Figure 1E] FIG. 1E is a side view of one of the sample carriers and sample vessels of FIG. 1D according to one or more embodiments. [Figure 1F] FIG. 1B is an isometric close-up view of a portion of the track of FIG. 1A including two sample carriers holding sample vessels, the sample vessels containing samples, and the sample carriers being independently movable by linear motors, according to one or more embodiments. [Figure 1G] FIG. 1F is a side view of one of the sample carriers and sample containers of FIG. 1F, according to one or more embodiments. [Figure 2] FIG. 1B is a block diagram of an embodiment of a track of the diagnostic laboratory system of FIG. 1A modeled in software as multiple adjacent blocks, according to one or more embodiments. [Figure 3]3A-3D are expanded views of certain blocks of the diagnostic laboratory system blocks of FIG. 1A and the block diagram of FIG. 2, according to one or more embodiments. [Figure 4] 1B illustrates a portion of the track of FIG. 1A showing the movement of a first sample carrier and a second sample carrier, according to one or more embodiments. [Figure 5-1] 5A-5H are diagrams illustrating the portion of the track shown in FIG. 4 at various time steps, according to one or more embodiments. [Figure 5-2] Same as above. [Figure 6] 5A-5H illustrate an example of two blocks, each with a respective queue of block commands for the example shown in FIGS. 5A-5H, according to one or more embodiments. [Figure 7] 7A-7C illustrate instructions for implementing block commands for transitions relating to time T=2 in FIG. 6, where the sample carrier is moved between blocks, in accordance with one or more embodiments. [Figure 8] FIG. 1B is a block diagram of another embodiment of the track of the diagnostic laboratory system of FIG. 1A modeled in software as multiple adjacent blocks, some of the blocks having a different movement pattern than the track embodiment of FIG. 2, in accordance with one or more embodiments. [Figure 9] FIG. 1 illustrates a three-dimensional block diagram representing a portion of a multi-level track in a diagnostic laboratory system capable of moving sample carriers and / or sample containers in three dimensions, according to one or more embodiments. [Figure 10] 1 is a flow diagram of a method for operating a diagnostic laboratory system for analyzing a biological sample, according to one or more embodiments. [Figure 11] 1 shows a flow diagram of a method for moving a sample carrier within a diagnostic laboratory system for analyzing biological samples, according to one or more embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0011] An automated diagnostic laboratory system can transport sample containers to different instruments via trucks. A routing program can determine the path on the truck that each sample container takes to reach an instrument that will perform a specific test on the sample stored in the sample container. As more sample types and testing capabilities are added to the diagnostic laboratory system, the routing becomes more complex. For example, sample containers may have to overtake and / or yield to each other at specific times to reach a specific instrument at a specific time. As high-priority samples are added, the routing becomes even more complex because the routing must be updated to allow lower-priority samples to yield to the higher-priority samples.

[0012] Diagnostic laboratory systems can be arranged in different physical configurations (e.g., truck and instrument layouts). Routing programs generally must be customized for the specific diagnostic laboratory configuration being used. However, customizing the routing program for each different configuration is difficult and increases the cost of implementing a diagnostic laboratory system.

[0013] Embodiments of the diagnostic laboratory systems and routing methods described herein use a dynamic routing algorithm to transport sample containers on one or more tracks throughout the laboratory system. Each track can be modeled in software via a computer as small segments or blocks, with each block representing a portion of the track configured to carry only one sample carrier at a time. Sample carrier movement and tracking is based on the movement of the sample carrier from one block to an adjacent block, rather than the entire track. Each block can be controlled by a segment controller, which determines and / or controls, for example, whether and / or how the sample carrier moves into and / or out of each block. A segment controller can control one or more blocks (e.g., one, two, three, four, five, or more blocks).

[0014] Each block can have a movement pattern associated with it (e.g., up, down, left, right as shown in the plan view) that indicates the direction in which sample carriers are allowed to move into and / or out of that block. For example, a particular block can only accept sample carriers from the left and pass them one at a time to an adjacent block to the right (e.g., a target block). An intersecting block can, for example, accept sample carriers from the left and pass them to an adjacent target block to the right or below (as shown in the plan view). Movement from one block to an adjacent target block is only allowed if the target block is unoccupied. If the target block is occupied, the sample carrier waits until the target block is free, which means that the target block does not have any sample carriers.

[0015] Alternatively, instead of modeling blocks, the track layout can be represented as a graph of nodes and edges, where the nodes can be similar to blocks and the movement patterns can define the edges connecting the nodes. A graph representation of the track layout is more general than a block model of the track layout (using a Cartesian grid). For example, such a graph can represent a track layout with non-uniform block sizes. This duality of representation (Cartesian grid vs. graph) allows for flexible software programming choices within a routing program for routing sample carriers throughout a diagnostic laboratory system.

[0016] In some embodiments, blocks can be as small as possible to allow for maximum traffic within the system, yet large enough so that each block can still have at least one sample carrier within its boundaries. Block size, including each block's movement pattern (e.g., up, down, left, right), can be determined from the physical layout of the track, the placement and capabilities of associated segment controllers and track sensors, and / or the dimensions of the sample carriers. A routing program executed by a system controller or similar computer can then configure the routing of sample carriers, for example, based on a software model of the blocks representing the track, with the routing being based on the movement of the sample carrier from one block to an adjacent block.

[0017] In some embodiments, the routing program can include input of the current positions of all sample carriers as well as a corresponding list of sample carrier destinations. The routing program can then generate a routing plan that can include a respective list of blocks through which each sample carrier will travel to reach its destination. In some embodiments, the routing program can generate a corresponding list of individual sequential steps (i.e., a queue of block commands) for each sample carrier and transmit those sequential steps to one or more segment controllers for execution, each segment controller controlling the movement of the sample carrier through one or more respective blocks. In other embodiments, a segment controller can receive the routing plan and generate a corresponding list of individual sequential steps (a queue of block commands) for each block under its control. Exemplary sample carrier steps can include moving to an adjacent target block in step S1 or remaining in a fixed position in step S2 (e.g., when another sample carrier is first moving through an adjacent intersecting block or until the adjacent block is free for a sample carrier). As described above, blocks are configured to be occupied by only one sample carrier at a time. Thus, if a target block is occupied, the sample carrier cannot move to that target block until the target block is free. Note that for each sample carrier step, the positions of all sample carriers are known to avoid collisions.

[0018] In some embodiments, each block command may include the time (e.g., time of day or relative time step, e.g., T1, T2, etc.) at which the block command is to be executed (e.g., to start the block command), an IN or OUT command (e.g., whether the sample carrier is entering or leaving the block), a sample carrier identification (e.g., identification of the sample carrier entering or leaving the block), and / or the direction of movement of the sample carrier into or out of the block (e.g., up, down, left, right, etc.).

[0019] In one or more embodiments, each block can have a set of block commands associated with it, and these block commands depend on the order in which the sample carriers arrive at the block. Therefore, the actual time indicated for which the block commands should be executed may be ignored. For example, if the sample carrier waits at a block (e.g., for a predetermined period of time, until a predetermined time, until an adjacent target block is empty, until a sample container is ready to be moved from an adjacent block to the block, until a segment controller controlling the block receives a signal from another segment controller, etc.), a WAIT command can be included as a block command, but this needs to be executed for longer than originally planned. In other embodiments, the routing plan can be executed for less time than originally planned. Thus, the routing plan can be event-driven, with each block command of the blocks being executed in order. Therefore, the original routing plan can be executed accurately without strictly adhering to the times or relative time steps included in the block commands.

[0020] The track's block software model provides simpler routing calculations. For example, by converting a time-driven routing plan to an event-driven routing plan (e.g., waiting until an empty target block is available), routing can be performed asynchronously, thereby reducing network latency requirements. In addition, after a routing plan (in some embodiments, a block command) is transmitted to a segment controller, the only communication required is between the segment controllers of adjacent blocks (e.g., to ensure that the sample carrier is moved into an unoccupied adjacent block). In some embodiments, this communication can be limited to a signal indicating that the block is empty.

[0021] These and other systems and methods are described in more detail below with reference to FIGS. 1A-11.

[0022] Referring now to FIG. 1A, FIG. 1A shows a diagram of an exemplary embodiment of an automated diagnostic laboratory system 100 according to one or more embodiments. The laboratory system 100 may include multiple instruments 102 configured to process sample containers 104 (some labeled) and perform analyses or tests on biological samples contained within the sample containers 104. The laboratory system 100 may have a first instrument 102A and a second instrument 102B. In addition, the laboratory system 100 may include a third instrument configured as a sample handler 102C. The sample handler 102C is configured to accept the sample containers 104 into the laboratory system 100. The first instrument 102A and / or the second instrument 102B may perform analyses on samples placed within the sample containers 104 (e.g., sample 162A in FIG. 1D ). Other embodiments of the laboratory system 100 may include more or fewer instruments.

[0023] The samples placed in the sample containers 104 can be various biological specimens collected from individuals, such as patients being evaluated by a medical professional. The samples can be collected from the patient and placed in the sample containers 104. The sample containers 104 can then be delivered to the laboratory system 100. The sample containers 104 can be loaded into the sample handler 102C. The sample containers 104 can be transferred from the sample handler 102C into sample carriers 108 (some labeled), which transport the sample containers 104 throughout the laboratory system 100, such as instruments 102, by truck 110. After the sample containers are introduced into the laboratory system 100 and placed on the sample carriers, the sample carriers are then instructed to visit a specific set of destinations (i.e., instruments 102 and / or other components or locations). The set of destinations can be a specific sequence. For example, the sample containers may need to first visit a centrifuge, followed by a decapper. In some situations, the sample container may be required to reach these destinations within a specific time window. For example, the specimen container may be required to be aspirated within a specific period of time after decapping. The laboratory system 100 includes a first sample container 104A disposed within a first sample carrier 108A and a second sample container 104B disposed within a second sample carrier 108B, as described in more detail herein.

[0024] The track 110 is configured to enable the sample carriers 108 to move throughout the laboratory system 100, including to and from the sample handler 102C, in response to transport commands described herein. For example, the track 110 can extend proximate to and / or around at least some of the instruments 102 shown in FIG. 1A. The instruments 102 can have devices such as robots (not shown in FIG. 1A) that transfer sample containers 104 to and from the sample carriers 108. The track 110 can have electronic transport components (not shown in FIG. 1A) that move the sample containers 104 through the sample carriers 108 and / or monitor the location of the sample containers 104 on the track 110.

[0025] The instrument 102 and transport components may include or be coupled to a computer 120 (e.g., a central system controller) configured to execute one or more programs that control the operation of the laboratory system 100. The computer 120 may be configured to communicate with the instrument 102, the transport components, and other components of the laboratory system 100. The computer 120 may include a processor 122 configured to execute programs, including programs other than those described herein. The programs may be implemented in computer code. In some embodiments, the computer 120 may be located remotely from the instrument 102. Additionally, in some embodiments, the computer 120 may control the operation of multiple different laboratory systems. Thus, data generated by the laboratory system 100 may be stored and / or processed remotely from the laboratory system 100. The computer 120 may include or have access to a memory 124, which may store one or more programs and / or data described herein. The memory 124 and / or programs stored in the memory 124 may be referred to as a non-transitory computer-readable medium. In some embodiments, the memory may be located remotely from other components of the computer 120 .

[0026] The memory 124 may include a routing program 126 (e.g., computer code executable by the processor 122) configured to generate a path (e.g., a routing plan) for the sample carrier 108 (carrying the sample containers 104). The path may direct the sample carrier 108 to a particular one of the instruments 102 to perform a test on the sample in the sample container 104.

[0027] The automated diagnostic laboratory system 100 can also include one or more segment controllers 128. Each segment controller 128 can control the movement of the sample carrier 108 through one or more designated blocks of the track 110. Each segment controller 128 can include a processor, transceiver, etc., and memory that stores a block control program 130 (e.g., computer code executable by the processor). The block control program 130 is configured to generate instructions to move the sample carrier 108 to and through one or more designated blocks. Thus, each block control program 130 can generate instructions to activate particular transport components on the track 110 to move a particular sample carrier 108 to and / or through one or more designated blocks controlled by the segment controller 128 executing that block control program 130. Each segment controller 128 can be located around the track 110 at or near the block that the segment controller 128 controls. Each segment controller 128 can communicate with the computer 120 and / or with each other via Ethernet or other suitable networks using wired and / or wireless connections. Each segment controller 128 can include components other than those described above. In alternative embodiments, the functions performed by the segment controllers 128 can be performed by separate (parallel) processors in the computer 120 or another central computer, and the respective block control programs 130 of each segment controller 128 can be stored in the memory 124 or in the memory of another central computer.

[0028] In some embodiments, the routing program 126 can generate paths and / or instructions for routing individual sample carriers 108 to and through blocks 160. For example, the routing program 126 can identify which blocks the sample carriers 108 must pass through to reach the instrument. In some embodiments, the routing program 126 can also determine the appropriate block commands to execute for each block (e.g., a queue of block commands), and in other embodiments, individual segment controllers 128 can determine a queue of block commands to execute based on block path information provided by the routing program 126 (e.g., a list of blocks for a sample carrier including its determined path to its destination).

[0029] The workstation 132 can be electrically coupled to the computer 120 and can communicate with the computer 120. In some embodiments, the workstation 132 can be located remotely from the truck 110. The workstation 132 can include at least a display 134 and a keyboard 136. The workstation 132 enables a user of the laboratory system 100 to input data into the computer 120 and enables the computer 120 to output data to the user, such as via the display 134.

[0030] The illustrated track 110 includes dashed lines to indicate the routes or paths that the sample carriers 108 (and thus the sample containers 104) can take within the laboratory system 100. As shown in FIG. 1A, the sample carriers 108 can take many routes throughout the laboratory system 100. The routing program 126 generates instructions to guide the sample carriers 108 to move on these routes to designated instruments or other destinations at scheduled times to keep the laboratory system 100 operating efficiently. In some embodiments, the routing program 126 can determine the most efficient path for one or more of the sample carriers 108, taking into account the possibility of other sample carriers 108 traveling on the same path and / or to the same instrument or other destination. The segment controllers 128 (each executing a respective block control program 130) can activate transport components (described below) on the track 110 for the blocks under their control to move the sample carriers 108 on the paths determined by the routing program 126.

[0031] With further reference to FIG. 1B, FIG. 1B shows an enlarged portion of the track 110. The track 110 has different segments 140 that indicate movement of the sample carrier 108 in at least the x- and y-directions and change of direction between the x- and y-directions. Types of segments 140 include curved segments 140A that change the direction of the sample carrier 108 between the x- and y-directions and vice versa. Other types of segments 140 include crossing segments 140B that receive the sample carrier 108 from a first port and selectively output the sample carrier 108 to one of at least two other ports. The crossing segment 140B can also receive the sample carrier 108 from at least the first and second ports and output the sample carrier 108 to a third port. The track 110 can also include a straight segment 140C that continues the movement of the sample carrier 108 in a straight line.

[0032] The particular segments of track 110 are described in detail below with reference to the operation of routing program 126. First segment 142 is a straight segment extending in the x-direction. Second segment 144 is a curved segment extending in the y-direction and the x-direction. Third segment 146 is an intersecting segment extending in the y-direction, with a branch extending in the positive x-direction. Fourth segment 148 is another intersecting segment extending in the x-direction, with a branch extending in the negative y-direction. Fifth segment 150 is a curve, and sixth segment 152 is a curve that is a mirror image of fifth segment 150. Seventh segment 153 is parallel to first segment 142.

[0033] The track 110 can include transport mechanisms 154 (some labeled) configured to transport the sample carriers 108 on the track 110. In FIG. 1B, an example transport mechanism 154 is shown as being located below the track 110. In other embodiments, the transport mechanism 154 can be located beside the track 110, above the track 110, or any other suitable location. Examples of transport mechanisms 154 are described below with reference to FIGS. 1B-1G, and the transport mechanism 154 can include movable belts and rollers (not shown separately) that use friction to move the sample carriers 108, and magnetic devices (see, e.g., FIGS. 1F and 1G) that magnetically move the sample carriers 108 relative to the track 110. In yet other examples, the sample carriers 108 can be self-propelled on the track 110 (see, e.g., FIG. 1D), and in some embodiments, the sample carriers 108 can receive movement commands wirelessly from the computer 120, the segment controller 128, and / or the transport mechanism 154. The transport mechanism 154 is not limited to the examples given above. Any suitable mechanism for transporting the sample carriers 108 through the blocks via the tracks 110 can be used as the transport mechanism 154. The transport mechanism 154 can receive signals from the segment controllers 128 (through execution of the respective block control programs 130) that cause the transport mechanism 154 to operate.

[0034] The laboratory system 100 may also include a plurality of track sensors 156 (some of which are labeled in FIG. 1B ) configured to identify the position of the sample containers 104 and / or sample carriers 108 on the track 110. The track sensors 156 are shown as straight or curved, rectangular shapes adjacent to the segments 140 of the track 110. However, in some embodiments, the track sensors 156 may be an integral part of the track segments. The track sensors 156 may be any device that senses or determines the position of the sample carriers 108 and / or sample containers 104 and then transmits the position information to an associated segment controller 128 for processing by the block control program 130 and / or to the computer 120 for processing by the routing program 126. In some embodiments, the segment controller 128 may forward the position data received from the track sensors 156 to the computer 120. In some embodiments, the track sensors 156 may be small, individual elements positioned adjacent to the track 110. Examples of track sensors 156 include optical devices that read indicia (not shown) located on the sample carrier 108 and / or sample container 104, radio frequency identification devices (RFID) that read RFID tags (not shown) located on the sample carrier 108 and / or sample container 104, etc. Other track sensors that determine the position of the sample container 104 and / or sample carrier 108 may also be used.

[0035] 1C, which shows an enlarged portion of the first segment 142, which transports a first sample container 104A by a first sample carrier 108A and a third sample container 104C by a third sample carrier 108C. The track 110 is modeled in software into a plurality of blocks 160. The portion of the first segment 142 shown in FIG. 1C is shown as having four blocks, referred to individually as a first block 160A, a second block 160B, a third block 160C, and a fourth block 160D. Other numbers of blocks 160 may also be modeled for a given portion of the track 110. As described in more detail below, the transport mechanism 154 is configured to move the first sample carrier 108A and / or the first sample container 104A and the third sample container 104C and / or the third sample carrier 108C to and through adjacent blocks 160.

[0036] The sample carrier 108 (and sample container 104) can be moved via a linear motor, a belt, a signal, and / or power applied to the sample carrier 108 when a self-propelled sample carrier is used, etc. For example, the transport mechanism 154 can have hardware components associated with each of the blocks 160 configured to move the sample carrier 108 to and through each of the blocks 160. In the embodiment of FIG. 1C , the transport mechanism 154 moves the first sample carrier 108A from the first block 160A to the second block 160B and moves the third sample carrier 108C from the second block 160B to the third block 160C. In some embodiments, each of the blocks 160 can include a separate transport mechanism. In other embodiments, multiple blocks 160 can be associated with a single transport mechanism, which is configured to transport the first sample carrier 108A and the third sample carrier 108C between each of the blocks 160 independently.

[0037] In the embodiment of Figure 1C, the track sensor 156 is shown as being divided into a plurality of individual sensors. Each of the sensors can be configured to sense the position of a first sample carrier 108A in each of the blocks 160 and transmit that position information to one or more segment controllers 128 and / or computers 120 (for routing programs 126 and / or other components) associated with one or more blocks 160, respectively. The first sensor 156A senses the first sample carrier 108A in the first block 160A, the second sensor 156B senses the third sample carrier 108C in the second block 160B, the third sensor 156C senses the sample carrier 108 in the third block 160C (Figure 1A), and the fourth sensor 156D senses the sample carrier 108 in the fourth block 160D.

[0038] With further reference to FIG. 1D, FIG. 1D is an isometric close-up view of a portion of the track 110 of FIG. 1C. In the embodiment of FIG. 1D, a first sample container 104A contains a first sample 162A that can be received within a first sample carrier 108A and analyzed by one or more of the instruments 102 (FIG. 1A). The embodiment of FIG. 1D also includes a third sample container 104C received within a third sample carrier 108C. A third sample 162C is disposed within the third sample container 104C. The transport mechanism 154 of FIG. 1D can be a single mechanism that enables independent movement (e.g., by magnetic induction, etc.) of the first sample carrier 108A and the third sample carrier 108C into and out of the first block 160A and the second block 160B. For example, the transport mechanism 154 may cause the first sample carrier 108A to wait in the first block 160A while moving the third sample carrier 108C from the second block 160B to the third block 160C. The track sensor 156 may be configured to identify the location of the first sample carrier 108A and the third sample carrier 108C on the track 110 and transmit the position data to the associated segment controller 128 and / or routing program 126 (FIG. 1A). In some embodiments, the blocks 160 may each be slightly larger than the sample carriers 108. For example, the first block 160A may be slightly larger than the footprint of the first sample carrier 108A and the footprint of the third sample carrier 108C.

[0039] With further reference to FIG. 1E, FIG. 1E illustrates one embodiment of a first sample carrier 108A configured to be self-propelled. The first sample carrier 108A can include a housing 168 within which a motor 170 and a receiver 172 can be disposed. The motor 170 can be coupled to wheels 174 extending from the housing 168. The receiver 172 can receive a transport command from one of the segment controllers 128 indicating that the first sample carrier 108A is to move from one block to an adjacent block, etc. The receiver 172 can then activate the motor 170, which rotates the wheels 174 to move the first sample carrier 108A. In some embodiments, a coil or the like can be located within the transport mechanism 154 to generate an electric field that provides power to the motor 170. In other embodiments, suitable power can be provided to the motor 170 by other methods and devices for moving the first sample carrier 108A.

[0040] 1F and 1G, which illustrate one embodiment of a transport mechanism 154 configured as a linear motor. In the embodiment of FIG. 1F, the transport mechanism 154 includes a coil 178 configured to generate a magnetic field in response to a signal generated by the segment controller 128 (FIG. 1A). A base 180 (FIG. 1G) of the housing 168 can be magnetized, such that a change in the magnetic field generated by the coil 178 can apply a force to the base 180. This force causes the first sample carrier 108A to move on the track 110.

[0041] The routing program 126 generates a path or route for moving the sample carrier 108 on the track 110 and, in some embodiments, a queue of block commands for moving the sample carrier accordingly. The queue of block commands can then be analyzed based on specific blocks within the generated path or route and transmitted to one or more segment controllers 128 that control the movement of the sample carrier through those specific blocks. The associated block control programs 130 of those one or more segment controllers 128 can then generate electrical signals that cause the transport mechanism 154 to move the sample carrier 108 along the track 110 in accordance with the block commands. In embodiments in which the sample carrier 108 is self-propelled, the segment controller 128 can include one or more transceivers or wireless transmitters that transmit instructions directly or indirectly to the sample carrier 108 when the segment controller receives position data generated by the track sensor 156 when an individual sample carrier 108 reaches a specific block under the control of the segment controller 128. The segment controller 128 can transfer the position data to the routing program 126 for updating path and block commands for other sample carriers 108 as described herein.

[0042] Ultimately, the routing plan generated by the routing program 126 causes the transport mechanism 154 to move each of the sample containers 104 (via the sample carriers 108) to a specific set of destinations, such as different ones of the instruments 102. These movements allow each of the sample containers 104 to visit the destinations in a specific sequence, such as visiting a centrifuge followed by a decapper. The routing plan can specify specific time windows that must be observed to visit specific destinations and perform specific time-sensitive tests. The laboratory system 100 can have hundreds or thousands of sample carriers 108 moving simultaneously to perform multiple different tests on samples (e.g., first sample 162A in FIG. 1D ) contained in the sample containers 104.

[0043] With further reference to FIG. 2 , FIG. 2 is an example block diagram 200 illustrating one embodiment of the track 110 modeled as a plurality of adjacent blocks 160 (some labeled). Other modeled block representations are possible and may include more or fewer blocks 160. In some embodiments, the routing program 126 or another program may electronically model the track 110 as a plurality of blocks 160. The routing program 126 then generates a routing plan for routing individual ones of the sample carriers 108 to and through adjacent ones of the blocks 160. In some embodiments, the routing program 126 may generate a queue of block commands based on the routing plan for all of the blocks 160 and then transmit those block commands to the appropriate segment controller 128 for execution. In other embodiments, the routing plan is transferred to the appropriate segment controller 128, which then generates a respective queue of block commands for the blocks under its control. The block commands instruct individual ones of the blocks 160 to receive specific sample carriers 108 from specific adjacent blocks and to issue those sample carriers 108 to other specific adjacent blocks. In accordance with the execution of the generated block commands, individual segment controllers 128 can instruct specific transport mechanisms 154 to move sample carriers 108 from one block to its adjacent block when the adjacent block is free. One advantage of block modeling is that it makes it much easier to plan, execute, and monitor the movement of sample carriers 108, because individual segment controllers 128 only need to consider the movement of sample carriers 108 from block to block, unlike the computer 120 (which runs the routing program 126) which directs all movements of all sample carriers 108 on the physical track 110.

[0044] The block diagram 200 models the physical space on the track 110 (through which the sample container 104 or sample carrier 108 can travel) as blocks 160. The embodiments herein describe moving a sample carrier 108 (carrying a sample container 104) from one block 160 to an adjacent block 160. Each block 160 has a movement pattern that indicates the allowed directions (indicated by arrows) in which the sample carrier 108 can move into and out of each block 160. By default, the movement pattern can be defined by the physical layout of the track 110. For example, a four-way intersection with four ports can have a default movement pattern into and out of each of the four ports. The movement pattern can indicate physical constraints that portions of the track 110 corresponding to one or more of the blocks 160 may only allow the sample carrier 108 to move in specific directions. The movement pattern for a particular block can be included in the associated block control program 130 for that block. In some embodiments, the movement pattern can be changeable. For example, software such as the routing program 126 and / or the block control program 130 (of the segment controller 128) can determine the direction of the movement pattern for each of the blocks 160. These directions can, for example, temporarily restrict some of the blocks to have only one direction of movement (e.g., left to right) through the block. Thus, in some embodiments, the movement pattern is not fixed and can be changed by the routing program 126 and / or the block control program 130, for example, in response to track component failures and / or changes in the routing plan.

[0045] 3A, which shows an expanded view of a first block 160A, which in some embodiments may be identical to at least blocks 160B, 160D, and 160E, as well as other blocks representing linear segments of track 110. Block 160A has a first port 300A and a second port 300B, indicated by a double-headed arrow between the first port 300A and the second port 300B. The double-headed arrow indicates permitted movement through first block 160A, allowing sample carriers 108 (and therefore sample containers 104) to be received by and egress from both the first port 300A and the second port 300B.

[0046] Referring again to FIG. 2, block 204 is a corner block corresponding to second segment 144 in FIG. 1B. Block 204 is configured to change the orientation of sample carrier 108 between the x- and y-directions. Further referring to FIG. 3B, FIG. 3B shows an enlarged view of block 204. Block 204 has a first port 302A and a second port 302B, indicated by a double-headed arrow between the first port 302A and the second port 302B. The double-headed arrow indicates permitted movement through block 204, allowing sample carrier 108 (and thus sample container 104) to be received by and exit both first port 302A and second port 302B, thereby changing the orientation of sample carrier 108 between the x- and y-directions.

[0047] Referring again to FIG. 2, block 206 is an intersection block corresponding to the third segment 146 of FIG. 1B. Block 206 is configured to accept a sample carrier into a first port and transport the sample carrier out one of two other ports. Further referring to FIG. 3C, FIG. 3C shows an expanded view of block 206. Block 206 has a first port 304A, a second port 304B, and a third port 304C, indicated by arrows between the first port 304A, the second port 304B, and the third port 304C. These arrows indicate permitted movement through block 206; a sample carrier 108 (and thus a sample container 104) can be accepted into one port and exit one of the other two ports, or accepted into one of the two ports and exited through the third port.

[0048] Other blocks shown in Figure 2 include block 208, which is an intersection block corresponding to the fourth segment 148 of Figure 1B. Block 208 is configured similarly to block 206. Block 210 is a corner block corresponding to the fifth segment 150 of Figure 1B, and block 212 is a corner block corresponding to the sixth segment 152 of Figure 1B. Blocks 210 and 212 are configured similarly to block 204. Block 210 is a mirror image of block 204, and block 212 is a mirror image of block 210.

[0049] Block 160H shown in Figure 2 is a four-pronged cross block corresponding to cross segment 190 of Figure 1A. Block 160H is configured to accept a sample carrier 108 into a first, second, third, or fourth port and to exit the sample carrier 108 from the first, second, third, or fourth port. With further reference to Figure 3D, Figure 3D shows an expanded view of block 160H. Block 160H has a first port 306A, a second port 306B, a third port 306C, and a fourth port 306D, through which a sample carrier 108 can enter or exit.

[0050] To illustrate an example of moving sample containers as described below, reference will now be made to specific blocks among blocks 160 corresponding to first segment 142 (FIG. 1B) and parallel seventh segment 153 of track 110. Blocks 160A-160J (FIG. 2) correspond to portions of first segment 142 and seventh segment 153 in physical track 110. In this example, the portion of first segment 142 of physical track 110 is configured to have five of the sample carriers 108, and thus five blocks 160A-160E. The portion of seventh segment 153 of physical track 110 is also configured to have five of the sample carriers 108, and thus five blocks 160F-160J. In this example, each of blocks 160A-160J is configured to have only one sample carrier 108 at a time, and movement of sample carriers 108 is from one block to an adjacent free block. In some embodiments, the block 160 can be configured to have more than one sample carrier (e.g., in a sufficiently large block), yet the distance between the sample carriers 108 within the block is sufficient to avoid collisions.

[0051] In summary, a queue of block commands is generated for each of the blocks 160, and the queue of block commands can indicate where the sample carrier 108 should enter the block 160 and where the sample carrier 108 should exit the block 160. Each individual segment controller 128 executes the block commands associated with one or several blocks 160 under its control, i.e., one controller does not control the movement of all sample carriers in the entire track 110.

[0052] Inputs to the routing program 126 may include the physical layout of the track 110, the current locations of the sample carriers 108, and a corresponding list of destinations for each of the sample carriers 108. The routing program 126 or another program may model the track 110 as multiple blocks based on input parameters such as, for example, track layout, track dimensions, sample carrier dimensions, number of allowed sample carriers per block, number / capabilities / location of segment controllers and track sensors, etc.

[0053] Based on the above modeled track 110 and sample carrier 108 inputs, the routing program 126 generates a routing plan that includes the path (and associated blocks) to be followed by each sample carrier 108 currently positioned on the track 110. Thus, the routing program 126 determines which of the blocks 160 each sample carrier will proceed through. After the routing plan is generated, it is converted (by the routing program 126 or the associated segment controller 128) into a queue of block commands for each of the blocks 160. The block commands may include a time step, whether the sample carrier is entering or exiting the block, sample carrier identification, and the direction of sample carrier movement. In some embodiments, the positions of all sample carriers 108 at each time step may be indicated. If the sample carrier needs to wait in a block for a specific amount of time (or until a specific time), the block commands may include an appropriate wait command.

[0054] At this point in the path plan, each of the blocks 160 has an associated set of block commands that depend on the order in which the sample carriers 108 arrive at and / or depart from the blocks 160. As described herein, in some embodiments, the time step for each of the block commands may be ignored because the movement of the sample carriers 108 is event-driven rather than time-driven. As long as each queue of block commands is executed in order (by the respective segment controllers 128), the path plan will execute correctly. Specifically, each of the sample carriers 108 will arrive at its destination in the correct order without collisions. In some embodiments, the arrival times of the sample carriers 108 may differ from the original path plan, but the arrival order of the sample carriers can be maintained.

[0055] In some embodiments, the path plan may be generated or revised continuously. For example, the path plan may be generated or revised after a predetermined number of time steps have been executed. In another embodiment, additional path plans may be generated in response to track sensors indicating availability within blocks at and around the sampler handler 102C and / or instruments 102A, B. In other embodiments, the path plan may be generated or revised when one or more new sample containers are received into the laboratory system 100. The path plan may also be generated or revised when changes occur in the laboratory system 100 that require the sample containers 104 to visit a different instrument, such as when an instrument fails or when supplies for an instrument are depleted.

[0056] The methods described herein are illustrated in the examples below. Referring to Figures 1A and 4, a first sample carrier 108A is programmed to move from location 182A to destination 182B, and a second sample carrier 108B is programmed to move from location 184A to destination 184B. Figure 4 shows an enlarged view of portions of the first segment 142 and seventh segment 153 (Figure 1B) of the track 110.

[0057] 5A-5H, which are block diagrams of the portion of the track 110 shown in FIG. 4 at various time steps, showing the first sample carrier 108A and the second sample carrier 108B in various positions. The states of the track 110 and block 160 shown in FIGS. 5A-5H are planned by the routing program 126. The block diagram in FIG. 5A shows the first sample carrier 108A located at location 182A (FIG. 4), which corresponds to block 160A. The destination of the first sample carrier 108A is destination 182B (FIGS. 4 and 5A), which corresponds to block 160J. The second sample carrier 108B is located at location 184A (FIG. 4), which corresponds to block 160F. The destination of the second sample carrier 108B is destination 184B, which corresponds to block 160E. The state of track 110 and block 160 in Figure 5A is the initial state at time 0 or T = 0. To plan the paths of the first sample carrier 108A and the second sample carrier 108B, the locations of the sample carriers 108 can be identified and transmitted to the routing program 126.

[0058] Figure 5B shows the state of the track at the next time step, i.e., T=1. At this stage in the path planning, the routing program 126, or the block control program 130 of the segment controller 128 associated with the blocks shown in Figure 5B, is generating block commands to move the first sample carrier 108A to block 160B and the second sample carrier 108B to block 160G. For example, the first segment controller 128 can control the movement of the sample carrier 108 (Figure 1A) within block 160A, the second segment controller 128 can control the movement of the sample carrier 108 within block 160B, and the third segment controller 128 can control the movement of the sample carrier 108 within block 160C. Thus, both the first segment controller 128 and the second segment controller 128 can generate instructions for the transport mechanism 154 to move the first sample carrier 108A from block 160A to block 160B based on the block commands determined from the path planning. The segment controller 128 (not shown) associated with block 160F and block 160G can also generate instructions based on the block commands determined from the routing plan to cause the transport mechanism 154 to move the second sample carrier 108B from block 160F to block 160G.

[0059] To reach their respective final destinations, both the first sample carrier 108A and the second sample carrier 108B must occupy blocks 160C and 160H. Therefore, either the first sample carrier 108A or the second sample carrier 108B must wait until the other sample carrier 108B or 108A passes through blocks 160C and 160H. Block commands generated (by the routing program 126 or the block control program 130 of the segment controller 128 associated with blocks 160C and 160H) direct sample carriers with higher-priority samples to pass through blocks 160C and 160H first. If none of the sample containers have a higher-priority sample, the generated block command can direct a sample carrier that may be blocking other sample carriers with higher-priority samples to proceed first. In other embodiments, the block command can direct the sample carrier carrying the oldest sample to proceed first. Other factors can also be used to determine the order of the sample carriers.

[0060] In this example, the sample carried by the first sample carrier 108A has priority over the second sample carrier 108B, so one or more appropriate segment controllers 128 generate a command to move the first sample carrier 108A to block 160C at T=2, as shown in Figure 5C. Because the first sample carrier 108A has priority, the generated block command directs the second sample carrier 108B to wait in block 160G. The one or more appropriate segment controllers 128 then generate a command to move the first sample carrier 108A to block 160H at T=3, as shown in Figure 5D, while the second sample carrier 108B continues to wait in block 160G.

[0061] At time step T=4 (FIG. 5E), the generated block command causes the appropriate segment controller 128 to move the first sample carrier 108A from block 160H to block 160I, as shown in FIG. 5E. The generated block command also causes the appropriate segment controller 128 to move the second sample carrier 108B from block 160G to block 160H, as shown in FIG. 5E. From this time onward, the generated block command (via one or more appropriate segment controllers 128) causes the sample carriers to be moved to the appropriate destinations 182B, 184B (FIG. 4). That is, at time step T=5, the appropriate segment controller 128 moves the first sample carrier 108A from block 160I to destination 182B, block 160J, as shown in FIG. 5F. Also at time step T=5, the appropriate segment controller 128 moves the second sample carrier 108B from block 160H to block 160C. The second sample carrier 108B then moves from block 160C to block 160D at time step T=6, as shown in Figure 5G, via execution of the generated block commands by the appropriate segment controller 128. The second sample carrier 108B then moves from block 160D to block 160E at T=7, as shown in Figure 5H, via execution of the generated block commands by the appropriate segment controller 128. In this example, block 160E is the destination 184B for the second sample carrier 108B.

[0062] In some embodiments, after a routing plan is generated that includes a list of all blocks to be traversed by the sample carrier, the routing plan can be converted by processor 122 (executing routing program 126) or one or more processors in one or more respective segment controllers 128 (executing respective block control programs 130) into a queue of block commands for each of the blocks 160. Each queue of block commands can include a carrier identification, a direction of movement of the sample carrier, and the block the sample carrier is leaving from and / or the block the sample carrier is entering.

[0063] With further reference to FIG. 6, FIG. 6 illustrates an example of two queues of block commands, one for block 160B and the other for block 160C, each relating to the above example shown in FIGS. 5A-5H. Separate queues of block commands can also be generated for each of blocks 160. The two queues of block commands shown in FIG. 6 can be generated and / or executed by the respective segment controllers 128 (FIG. 1A) for blocks 160B and 160C based on a routing plan generated by routing program 126. In other embodiments, the queues of block commands in FIG. 6 can also be generated by routing program 126 and forwarded by the respective processors and block control program 130 to the appropriate segment controllers 128 for execution.

[0064] In the queue of FIG. 6, the block commands indicate the time (T) at which the sample carrier enters, exits, or waits for block 160B and block 160C. For this example, no action is taken for block 160C before time step T=2. At time step T=1, block 160B receives the first sample carrier 108A from the left (block 160A) (see FIG. 5B). At time step T=2, block 160C receives the first sample carrier 108A from the left (block 160B) (see FIG. 5C). At time step T=3, the first sample carrier 108A moves out of block 160C and into block 160H, which is positioned downward, as shown in FIG. 5D. At step T=3, no action is taken for block 160B, and therefore it does not appear in the queue of block commands for block 160B. At time step T=4, no action has been taken for blocks 160B and 160C (see FIG. 5E), and therefore they do not appear in the queue of block commands for blocks 160B and 160C. At time step T=5, the second sample carrier 108B is accepted from block 160H into block 160C, which is now positioned upward, as shown in FIG. 5F. At time step T=6, the second sample carrier 108B is moved to the right into block 160D. If the carrier needs to wait in a block for a specific amount of time (or until a specific time step), a wait command can be added to the IN / OUT field.

[0065] In some embodiments, the queue of block commands is executed in order, although the actual timing associated with the time steps may be ignored. With further reference to FIG. 7, FIG. 7 shows detailed sub-commands for executing the block command associated with time step T=2 of FIG. 6, in which the first sample carrier 108A is moved from block 160B to block 160C. The sub-commands are executed from the top or first entry in the queue of block commands and may be executed by one or two appropriate segment controllers 128 (FIG. 1A) that control the movement through blocks 160B and 160C. As described herein, the commands and sub-commands may be executed in order regardless of time, resulting in event-driven or event-dependent commands and sub-commands rather than time-driven or time-dependent commands and sub-commands.

[0066] The subcommands shown in FIG. 7 relate to a block command to move the first sample carrier 108A from block 160B into block 160C. Based on FIG. 6, the movement is to the right, i.e., from block 160B to block 160C. The subcommands shown in FIG. 7 begin by initializing block 160B or configuring the appropriate segment controller 128 to control block 160B. As shown in FIG. 7, the first subcommand can be indicated as "pop entry from queue of block 160B." The subcommand further includes recognizing that the instruction is to move the first sample carrier 108A from block 160B to block 160C, which can be indicated in FIG. 7 as "assert entry for first carrier to exit block 160B toward block 160C." The next subcommand sends a message from the segment controller 128 controlling movement through block 160B to the segment controller 128 controlling movement through block 160C. This message requests that the first sample carrier 108A be moved from block 160B to block 160C.

[0067] The segment controller 128 associated with block 160C waits until a request to receive the first sample carrier 108A (e.g., in the form of an IN command) is received. This request may include information that the first sample carrier 108A is coming from block 160B and is received from the segment controller 128 associated with block 160B. The next sub-command is shown in Figure 7 as "Wait until the entry above in the block 160C queue is IN for the first carrier." Because commands, and therefore sub-commands, are event-driven, the segment controller 128 for block 160C waits until the sub-command related to receiving the first sample carrier 108A is next in the processing order.

[0068] The next subcommand in the example of FIG. 7 is to wait until block 160C is free (i.e., there are no sample carriers in block 160C), which is indicated as "wait until block 160C is free." The track sensor 156 (FIG. 1B) can send free status data to the segment controller 128 associated with block 160C, which can determine whether block 160C is free. The segment controller 128 associated with block 160B can be configured to request the free status of block 160C. The next subcommand prepares block 160C to receive the first sample carrier 108A, which is indicated as "prepare for arrival of first carrier." This preparation can include initializing the transport mechanism 154 associated with block 160C to move the first sample carrier 108A into block 160C.

[0069] A response to the request sent from the segment controller 128 associated with block 160B is then returned to the segment controller 128 associated with block 160B. Specifically, the next subcommand executed causes the segment controller 128 associated with block 160C to send a command to the segment controller 128 associated with block 160B indicating that block 160C is free. The segment controller 128 associated with block 160B can then generate a command to move the first sample carrier 108A from block 160B to block 160C using the transport mechanism 154, as described above with reference to FIGS. 1D-1G. The transport mechanism command associated with the move subcommand can end in response to block 160C receiving the first sample carrier 108A and moving it to the center of block 160C. These subcommands are shown in FIG. 7 as "Receive first carrier from block 160B and move it to the center of block 160C." The segment controller 128 can move the sample carrier 108 to the center of the block 160, thus allowing the sample carrier 108 to exit the block 160 with minimal movement without interfering with or colliding with one another. For example, block 206 (FIG. 3C) is an intersection block, so the sample carrier 108 can exit through one of two ports. By having the sample carrier 108 in the center of the block 206, the sample carrier 108 is ready to exit directly to an adjacent block without having to be aligned with the adjacent block before being moved.

[0070] Referring again to FIG. 2, block diagram 200 shows block 160 with a motion pattern that restricts sample carrier 108 to move on track 110 (FIG. 1) only as indicated by the double-headed arrow. In other embodiments, the motion pattern can be more restrictive. For example, the motion pattern can allow only one-way movement through a particular block, or can restrict exit from and / or entry to a particular intersection block. In some embodiments, the segment controller 128 and / or routing program 126 can set the motion pattern.

[0071] 8, which shows a block diagram 800 of a block 160 having a different motion pattern than block 160 of FIG. 2. In some embodiments, the user and / or the routing program 126 (FIG. 1A) can determine the motion pattern. In the embodiment of FIG. 8, blocks 160A, 160B, 160D, and 160E have a unidirectional motion pattern, allowing only left-to-right motion. Block 160H has a motion pattern that does not allow upward motion (as shown on the page) to block 160C. Block 160C has a motion pattern that does not allow motion to the left of block 160C. The segment controller 128 (FIG. 1A) can generate block commands that move the sample carrier 108 according to the motion pattern.

[0072] 2 and 8, the blocks 160 are shown as squares or rectangles. Other block shapes may be used. For example, pentagonal blocks may be used to represent intersecting segments with five ports. The movement of the sample carriers 108 and sample containers 104 is described in a two-dimensional plane. Accordingly, the blocks 160 are also described in two dimensions. In other embodiments, the movement of the sample containers 104 and / or sample carriers 108 may be three-dimensional, such as X, Y, and Z (e.g., normal to the track 110), as described below in connection with FIG. 9. In such embodiments, one or more of the blocks 160 may be three-dimensional, such as cubic in shape.

[0073] Referring to FIG. 9, FIG. 9 shows a three-dimensional block diagram 900 of a portion of a track (not separately shown) that can move sample carriers 108 (FIG. 1A) carrying sample containers 104 in three dimensions. That is, in some embodiments of the automated diagnostic laboratory system 100, the transport system can have two or more levels, and one or more elevator-type mechanisms can move sample carriers 108 from blocks on one level to blocks on another level. In the embodiment of FIG. 9, the sample carriers 108 are configured to move in the x, y, and z directions to adjacent empty blocks. Block 902, for example, has a motion pattern that restricts motion to only the x and y directions. Block 904, for example, has a motion pattern that restricts motion to only the y and z directions. Other blocks may have other motion patterns. The routing program 126 routes the sample carriers 108 to and from adjacent blocks or cubes, as described above.

[0074] 10, which illustrates a flow diagram of a method 1000 of operating a diagnostic laboratory system (e.g., laboratory system 100) for analyzing a biological sample (e.g., sample 162A). Method 1000 includes, at block 1002, providing a track (e.g., track 110) within the diagnostic laboratory system, the track extending between a plurality of instruments (e.g., instruments 102).

[0075] The method 1000 includes providing a plurality of sample carriers (e.g., sample carriers 108) movable on a track at block 1004. The sample carriers 108 can move sample containers 104 on a track 110 from the sample handler 102C to one or more of the instruments 102 and then back to the sample handler 102C.

[0076] At block 1006, the method 1000 includes modeling, via the computer in software, a track (e.g., track 110) as a plurality of blocks (e.g., blocks 160), each block including a movement pattern indicating allowed directions in which multiple sample carriers may move into or out of the block. In some embodiments, the block 160 may be large enough to have a single sample vessel, but smaller than two of the sample vessels 108 placed side by side. The movement pattern defines the allowable movement through each of the blocks 160.

[0077] The method 1000 includes sensing the vacancy of a first block (e.g., block 160B) via a track sensor at block 1008. In some embodiments, the sample carrier 108 can only move into an empty block, and therefore the vacancy status of the block 160 must be determined before the sample carrier 108 is moved on the track 110.

[0078] Further, the method 1000 includes, at block 1010, moving a sample carrier from a second block adjacent to the first block into the first block in response to sensing an empty space in the first block.

[0079] 11, which illustrates a flow diagram of a method 1100 for moving a sample carrier (e.g., first sample container 108A) within a diagnostic laboratory system (e.g., laboratory system 100) for analyzing a biological sample (e.g., sample 162A). Method 1100 includes, at block 1102, providing a track (e.g., track 110) within diagnostic laboratory system 100, where track 110 extends between a plurality of instruments (e.g., instruments 102).

[0080] At block 1104, the method 1100 includes providing a sample carrier (e.g., sample carrier 108A) that carries a biological sample (e.g., biological sample 162A) contained in a sample container (e.g., sample container 104), the sample carrier being movable on a track (e.g., track 110).

[0081] At block 1106, method 1100 includes modeling, via the computer in software, a track (e.g., track 110) as a plurality of blocks (e.g., blocks 160), each block including a movement pattern indicating allowed directions in which a sample carrier (e.g., sample carrier 108A) may move into and out of that block, and each block configured to have only one sample carrier at a time. In some embodiments, block 160 can be, for example, slightly larger than the largest sample carrier and smaller than the size of two sample carriers placed side by side.

[0082] At block 1108, the method 1100 includes providing a plurality of segment controllers (segment controller 128) configured to control transport of a sample carrier (e.g., sample carrier 108A) through a plurality of blocks (e.g., blocks 160), the movement pattern of each block being defined by the segment controller associated with that block. In some embodiments, a single segment controller can be associated with multiple blocks (e.g., blocks 160).

[0083] The method 1100 includes, at block 1110, identifying at least one test to be performed on a biological sample using at least one instrument (eg, instrument 102).

[0084] At block 1112, the method 1100 includes using a routing program (e.g., routing program 126) to generate a routing plan for a sample carrier (e.g., sample carrier 108A) that transports a biological sample (e.g., biological sample 162A) through a sample container (e.g., sample container 104), the routing program including a list of blocks through which the sample carrier will travel to reach at least one instrument.

[0085] The method 1100 includes generating a queue of block commands for each block in the list of blocks (through which the sample carrier will travel) at block 1114. The block commands can be generated by a routing program running in the computer or by a block control program running in the segment controller. The block commands can include receiving the sample carrier from an adjacent block, moving the sample carrier to a specific adjacent block, and waiting, which can include holding the sample carrier within the block.

[0086] Further, the method 1100 includes moving the sample carrier through the blocks in the list of blocks (e.g., blocks 160) based on the queue of block commands for each block in the list of blocks, at block 1116. For example, the sample carrier 108A may move between adjacent ones of the blocks 160, and the movement may be in a direction toward an instrument on which a test is to be performed.

[0087] While the disclosure is susceptible to various modifications and alternative forms, specific method and apparatus embodiments have been shown by way of example in the drawings and are herein described in detail. It will be understood, however, that the particular methods and apparatus disclosed herein are not intended to limit the disclosure.

Claims

1. 1. A method of operating a diagnostic laboratory system for analyzing a biological sample, comprising: providing a track within the diagnostic laboratory system, the track extending between a plurality of instruments; providing a plurality of sample carriers movable on a track; modeling the track in software via the computer as a plurality of blocks, each block including a movement pattern indicating allowed directions in which the sample carrier may move into or out of the block; sensing an empty first block via a track sensor; in response to sensing the first block being empty, moving the sample carrier from a second block adjacent to the first block into the first block; The method comprising:

2. 2. The method of claim 1, wherein each block is configured to have only one sample carrier at a time.

3. The method of claim 1 , further comprising providing one or more segment controllers programmed to control transport of the plurality of sample carriers through the plurality of blocks.

4. 2. The method of claim 1, wherein sensing vacancy in the first block comprises sensing vacancy in the first block via a track sensor and communicating the sensing from the track sensor to a first segment controller associated with the first block, the first segment controller operative to control movement of the sample carrier within the first block.

5. The first segment controller also operates to control movement of the sample carrier within the second block; 5. The method of claim 4, wherein moving the sample carrier from the second block to the first block comprises moving the sample carrier from the second block to the first block in response to communication from the first segment controller to a transport component of a track operative to move the sample carrier to the sample carrier in the second block or from the second block to the first block.

6. Moving the sample carrier from the second block to the first block comprises: sending a request from a second segment controller associated with the second block to a first segment controller for the first block to receive the sample carrier from the second block; In response to communicating the clearance sensing from the track sensor to the first segment controller, transmitting a response from the first segment controller to the second segment controller; Including; 5. The method of claim 4, wherein moving the sample carrier from the second block to the first block comprises moving the sample carrier from the second block to the first block in response to the second segment controller receiving a response from the first segment controller.

7. 10. The method of claim 1, further comprising identifying at least one test to be performed on the biological sample using at least one instrument, and wherein moving comprises moving the sample carrier toward the at least one instrument.

8. obtaining a current position of each of a plurality of sample carriers; obtaining a destination for each of a plurality of sample carriers; generating, using a routing program, a routing plan for each sample carrier including a list of blocks through which the sample carrier will travel to reach its destination; generating a queue of block commands for each block based on a list of blocks in which each of the plurality of sample carriers will proceed; The method of claim 1 further comprising:

9. 9. The method of claim 8, wherein the queue of block commands for each of the plurality of blocks includes subcommands for receiving a sample carrier at the block, moving a sample carrier from the block, and waiting.

10. 9. The method of claim 8, wherein in response to sensing space in the first block, moving the sample carrier from the second block to the first block comprises executing a queue of block commands for the first block and a queue of block commands for the second block.

11. 1. A diagnostic laboratory system for analyzing biological samples, comprising: at least one device for preparing or testing a biological sample; a truck configured to transport sample containers configured to contain biological samples to be analyzed to and from at least one instrument; a computer; modeling the track in software as a plurality of blocks, each block including a movement pattern indicating one or more allowed directions in which a sample container may move into or out of the block; identifying at least one test to be performed on the biological sample by the at least one instrument; determining a path along the track to the at least one instrument, the path including at least a first block and a second block adjacent to the first block; a computer configured to: a first segment controller associated with the first block; a second segment controller associated with the second block and in communication with the first segment controller; Including; the first segment controller is operative to communicate that the first block is free; The diagnostic laboratory system, wherein the second segment controller operates to facilitate movement of the sample container from the second block to the first block in response to receiving communication from the first segment controller that the first block is free.

12. 12. The diagnostic laboratory system of claim 11, wherein each block is configured to have only one sample carrier at a time.

13. The diagnostic laboratory system of claim 11 , further comprising a plurality of segment controllers configured to control transport of the plurality of sample carriers through the plurality of blocks.

14. 14. The diagnostic laboratory system of claim 13, wherein the movement pattern of the block of the plurality of blocks is defined by a segment controller associated with the block of the plurality of blocks.

15. 12. The diagnostic laboratory system of claim 11, wherein the second segment controller is configured to request the availability of the first block from the first segment controller.

16. 16. The diagnostic laboratory system of claim 15, wherein the first segment controller is operative to send a response to the second segment controller in response to sensing that the first block is free.

17. The diagnostic laboratory system is configured to transport a plurality of sample carriers, and the computer obtaining a current position of each of a plurality of sample carriers; obtaining a destination for each of a plurality of sample carriers; generating, with a routing program, a routing plan for each of the plurality of sample carriers, each routing plan including a list of blocks through which each of the plurality of sample carriers will travel to reach its destination; generating a queue of block commands for each block based on a list of blocks in which each of the plurality of sample carriers will proceed; 12. The diagnostic laboratory system of claim 11 configured to:

18. 20. The diagnostic laboratory system of claim 17, wherein the queue of block commands for each of the plurality of blocks includes subcommands for receiving a sample carrier at the block, moving a sample carrier from the block, and waiting.

19. 20. The diagnostic laboratory system of claim 17, wherein the first segment controller operates to execute a queue of block commands for a first block and the second segment controller operates to execute a queue of block commands for a second block.

20. 1. A method of moving a sample carrier within a diagnostic laboratory system for analyzing a biological sample, comprising: providing a track within the diagnostic laboratory system, the track extending between a plurality of instruments; providing a sample carrier containing a biological sample, the sample carrier being movable on a track; modeling, in software via a computer, the track as a plurality of blocks, each block including a movement pattern indicating one or more allowed directions in which the sample carrier may move into or out of that block, each block being configured to have only one sample carrier at a time; providing a plurality of segment controllers configured to control transport of the sample carrier through a plurality of blocks, the movement pattern of each block being defined by a segment controller associated with the block; identifying at least one test to be performed on the biological sample using at least one instrument; generating a routing plan for the sample carrier using a routing program, the routing plan including a list of blocks through which the sample carrier will travel to reach at least one instrument; generating a queue of block commands for each block in the list of blocks; moving the specimen carrier through the blocks in the list of blocks in response to a queue of block commands for each block in the list of blocks; The method comprising:

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