System and method for transporting and holding consumables in processing equipment

Abstract

To provide a system and method for transporting and holding consumables in processing equipment. [Solution] The system and method provide a supply of consumables to a processing machine that uses one or more consumables for each of a plurality of processes performed by the machine. The system includes a loading drawer that holds a carrier for receiving a plurality of consumables, and an input module for holding a carrier on which the plurality of consumables are supported and for providing the consumables for access by the machine. The conveyor includes a vertical lifter and a lateral actuator for moving the lift frame vertically and laterally, and for transporting the carrier on the lift frame between the loading drawer and the input module, between the loading drawer and one or more holding devices, or between the input module and one or more holding shelves, with or without consumables supported thereon.

Description

Technical Field

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[0001] Cross - reference to Related Applications This application claims priority under 35 U.S.C. § 119 to the filing date of U.S. Provisional Patent Application No. 62 / 815,184, filed Mar. 7, 2019, which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates to systems and methods for transporting and holding the supply of consumables provided to processing equipment in which the consumables are moved or otherwise manipulated.

Background Art

[0003] Equipment for performing multiple parallel processes and / or sequential individual processes often requires handling various consumables in the execution of each individual process. Such consumables can be used once per individual process or once per various steps of the process and then discarded. Thus, to enable the execution of the process, it must be possible to adequately supply such consumables to the equipment. For example, an analyzer for performing biological, chemical, biochemical, or other multi - step analysis processes on a sample substance can execute a number of individual procedures over a period of time. For example, the Panther® system and Panther Fusion® system available from Hologic, Inc. (Marlborough, MA) can process up to 320 samples in 8 hours and up to 750 samples in 15.2 hours. Multiple different samples can be processed in parallel and / or sequentially, and multiple processes (e.g., tests) can be performed on each sample being processed. Each process performed on each sample tested by the analyzer typically requires a separate reaction vessel such as a test tube, and in some cases, separate reaction vessels such as test tubes may be required for different steps of the process.

[0004] It is often desirable to maximize the throughput of a processing instrument by executing as many processes as possible over a given period of time, and for this purpose, it is equally desirable that the instrument operate continuously or nearly continuously with minimal interruption. Therefore, it is desirable to adequately supply the instrument with consumables to avoid interruptions in instrument operation due to the need to periodically reload consumables such as reaction vessels on an automated molecular analyzer. Furthermore, consumables must be provided in a manner that allows access to the instrument for use when processing samples; that is, consumables should not simply be stored in large quantities on the instrument, but require operator intervention to be supplied to the instrument in smaller processing units. Throughput can be further improved if additional consumables can be loaded into the instrument while the instrument is operating, without interrupting processing by the instrument. [Overview of the Initiative] [Means for solving the problem]

[0005] The systems and methods disclosed herein enable a user to load a sufficient number of consumables, such as reaction vessels, into the instrument without requiring further interaction from the operator, thereby supporting long-duration operation of the instrument for, for example, 4, 6, 8, 10, 12 hours, or longer. Therefore, the systems and methods disclosed herein are significant as an improvement over existing systems that require the operator to periodically return to the instrument to load additional consumables. Furthermore, the systems and methods disclosed herein enable the instrument to access all supplied consumables for processing, and furthermore, if even longer-duration operation of the instrument is desired, the systems and methods disclosed herein enable a user to load additional consumables into the instrument without interrupting the instrument's operation.

[0006] The following is a simplified overview to provide a basic understanding of some of the embodiments described herein. This overview is not a comprehensive overview of the subject matter described in the claims. It is not intended to identify or define the main or important elements of the subject matter described in the claims. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed explanations that will be presented later.

[0007] An aspect of the present disclosure is embodied in a device for transporting an assembly of consumables between a plurality of vertically spaced holding shelves. The device comprises a support chassis positioned laterally spaced relative to the plurality of holding shelves; a transport elevator coupled to the support chassis for moving the support chassis vertically between the plurality of holding shelves; a lift stand; and a scissors actuator connected to the support chassis, configured to laterally translate the lift stand relative to the support chassis between a first position laterally aligned with the support chassis at a laterally spaced position relative to the plurality of holding shelves and a second position laterally displaced from the support chassis and laterally aligned with one of the holding shelves.

[0008] In another embodiment, the apparatus further comprises a transporter that is transported on a lift platform and configured to be arranged on any of a plurality of holding shelves.

[0009] In another embodiment, the carrier comprises a base, a pair of support rails for slidably supporting consumables thereon, and elastic tabs located at the ends of each support rail and configured to releasably hold the consumables on the support rails.

[0010] In another embodiment, each elastic tab is attached to a portion of its respective support rail or is located at the end of an adjacent meandering spring.

[0011] In another embodiment, the transport elevator comprises two drive belts, each attached to a part of a support chassis; a drive pulley for each drive belt; a motor coupled to the drive pulley; and an idler pulley for each drive belt.

[0012] In another embodiment, the device further comprises an elevator home sensor configured to detect a locator flag extending from a support chassis.

[0013] In another embodiment, the scissors actuator comprises a first arm having a first end and a second end, and a second arm having a first end and a second end. The first arm and the second arm are rotatably connected to each other at an intermediate position between their respective first and second ends, the first arm being pivotably mounted to a support chassis at its first end and pivotably and translatably mounted to a lift frame at its second end, and the second arm being pivotably and translatably mounted to a support chassis at its first end and pivotably mounted to a lift frame at its second end.

[0014] In another embodiment, a first arm and a second arm are rotatably connected to each other by a swivel ring having an inner ring and an outer ring, the inner ring and the outer ring being rotatable relative to each other, the first arm being attached to the inner ring at its respective intermediate position, and the second arm being attached to the outer ring at its respective intermediate position.

[0015] In another embodiment, the second end of the first arm is pivotably and translatably attached to the lift frame by a sliding body slidably disposed in a linear slot formed in the lift frame, and the sliding body is rotatably attached to the second end of the first arm.

[0016] In another embodiment, the apparatus further includes rolling bearings disposed within a sliding body that rolls against the side of the slot during the lateral translation of the lift frame.

[0017] In another embodiment, the scissors actuator further comprises a motor coupled to the first end of the first arm, which provides a pivotal motion of the first arm powered by the motor.

[0018] In another embodiment, the scissors actuator is configured to translate the lift frame in one of two opposing lateral directions relative to the support chassis.

[0019] In another embodiment, the apparatus further comprises a carrier detection sensor associated with each holding shelf and configured to detect the presence of a carrier on the associated holding shelf.

[0020] Aspects of the present disclosure are embodied in a device comprising a plurality of vertically spaced holding shelves, a conveyor for transporting assemblies of consumables between the plurality of holding shelves, and a conveyor lift connected to the support chassis for vertically moving the support chassis between the plurality of holding shelves. The conveyor comprises a support chassis positioned laterally spaced relative to the plurality of holding shelves, a lift stand, and a scissors actuator configured to translate the lift stand laterally relative to the support chassis between a first position laterally aligned with the support chassis at a laterally spaced position relative to the plurality of holding shelves, and a second position laterally displaced from the support chassis and laterally aligned with one of the holding shelves.

[0021] In another embodiment, the apparatus further comprises a carrier that holds consumables, is transported on a lift platform, and is configured to be arranged in one of a plurality of holding shelves.

[0022] In another embodiment, each holding shelf includes a carrier detection sensor configured to detect the presence of a carrier on the corresponding holding shelf.

[0023] According to another aspect, the carrier includes a base, a pair of support rails for slidably supporting the consumables thereon, and elastic tabs located at the ends of each support rail and configured to releasably hold the consumables on the support rails.

[0024] According to another aspect, each elastic tab is attached to the respective support rail or is disposed at the end of a serpentine spring that is part of it.

[0025] According to another aspect, the carrier includes at least one opening formed in its bottom, and each holding shelf includes at least one carrier locator pin that protrudes from the holding shelf to engage with the opening formed in the carrier.

[0026] According to another aspect, the conveyor elevator includes two drive belts each attached to a part of the support chassis, a drive pulley for each drive belt, a motor coupled to the drive pulley, and an idler pulley for each drive belt.

[0027] According to another aspect, one of the holding shelves includes a carrier support configured to be movable laterally between a first position accessible by the conveyor for loading a plurality of consumables onto the carrier support and a second position accessible by the user.

[0028] According to another aspect, the apparatus further includes a carrier configured to be transported on a lift platform and arranged on any of a plurality of holding shelves, and one of the holding shelves includes a carrier support configured to be movable laterally between a first position accessible by the conveyor for loading a plurality of consumables onto the carrier support and a second position accessible by the user. The carrier support includes a carrier locking mechanism configured to lock the carrier within the carrier support when the carrier support moves to the second position and release the carrier when the carrier support moves to the first position so that the conveyor can remove the carrier from the carrier support.

[0029] According to another aspect, the carrier locking mechanism includes a pivoting latch configured to pivot between a first position not engaged with a portion of the carrier and a second position engaged with a portion of the carrier, and a sliding body latch configured to linearly translate between a first position not engaged with a portion of the carrier and a second position engaged with a portion of the carrier.

[0030] According to another aspect, the apparatus further includes a torsion spring coupled to the pivoting latch and biasing the pivoting latch to its respective second position engaged with a portion of the carrier, and a linear spring coupled to the sliding body latch and biasing the sliding body latch to its respective second position engaged with a portion of the carrier.

[0031] According to another aspect, the pivoting latch includes an upper end that engages a portion of the carrier on the carrier support when the carrier support is in the second position and the pivoting latch is in the second position, and a lower end that contacts a hard stop when the carrier support moves from its second position to its first position, thus rotating the pivoting latch from the second position to the first position, thereby releasing the carrier supported on the carrier support. The sliding body latch engages a portion of the carrier on the carrier support when the carrier support is in the second position and the sliding body latch is in the second position, and the sliding body latch contacts a hard stop that pushes the sliding body latch into the first position, and the carrier support is moved from its second position to its first position, thereby releasing the carrier supported on the carrier support.

[0032] In another embodiment, the carrier is longer than the lift stand such that the first and second ends of the carrier extend beyond the first and second ends of the lift stand, and each holding shelf includes a first shelf portion and a second shelf portion spaced at least the length of the lift stand. The conveyor is configured and controlled to convey a carrier supported on the lift stand from the lift stand to one of a plurality of holding shelves by moving the support chassis by a conveyor lift to a vertical position where the lift stand is above the holding shelves, moving the lift stand laterally by a scissors actuator to a position where the first and second ends of the carrier are aligned with the first shelf and second shelf portions of the holding shelves, and lowering the support chassis by a conveyor lift so that the stand moves between the first shelf and second shelf portions until the first and second ends of the carrier are supported on the first shelf and second shelf portions.

[0033] In another embodiment, each consumable comprises a multi-receiver unit including a plurality of receivers arranged in parallel and connected to one another, and the apparatus further comprises a carrier configured to be transported on a lift frame and arranged on one of a plurality of holding shelves. The carrier comprises a base, a pair of parallel support rails for slidably supporting a multi-receiver unit thereon, with at least one receiver of each multi-receiver unit positioned between the support rails, and elastic tabs located at the ends of each support rail and configured to releasably hold the multi-receiver unit on the support rails. One of the holding shelves comprises an input module configured to hold the carrier therein, the input module comprising an extruder configured to push one or more multi-receiver units supported on the carrier toward the end of the carrier.

[0034] In another embodiment, the input module is located on one side of the support chassis, one or more of the remaining holding shelves are located on the opposite side of the support chassis, and the scissors actuator is configured to translate the lift frame in one of two opposing lateral directions relative to the support chassis.

[0035] In another embodiment, each consumable comprises a multi-receiver unit including a plurality of receivers arranged in parallel and connected to one another, and the apparatus further comprises a carrier configured to be transported on a lift frame and arranged on one of a plurality of holding shelves. The carrier comprises a base, a pair of parallel support rails for slidably supporting a multi-receiver unit thereon, the support rails with at least one receiver of each multi-receiver unit positioned between the support rails, and stop flanges located at the ends of each support rail.

[0036] In another embodiment, at least one of the holding shelves includes a packing mechanism configured to move relative to a transport body held by the holding shelf and push the transported multi-receiving unit on the transport body until one of the final ends of the multi-receiving unit is pushed out from the support rail.

[0037] In another embodiment, the device further comprises a packaging mechanism position sensor configured to detect the stopping position of the packaging mechanism in which one of the final ends of the multiple receiver units is pushed out from the support rail, and to determine the number of multiple receiver units transported on the transport body based on the detected stopping position.

[0038] In another embodiment, the apparatus further comprises a position sensor mechanism for detecting the vertical position of a support chassis and the lateral position of a lift stand, and a control unit that controls a transport elevator and a scissors actuator and communicates with the position sensor mechanism. The control unit is configured to record the position of each holding shelf by moving the lift stand relative to each holding shelf until the lift stand contacts the positioning tab of the holding shelf, and by recording the vertical position of the support chassis and the lateral position of the lift stand detected by the position sensor mechanism when the lift stand contacts the positioning tab.

[0039] An aspect of the present disclosure is embodied in a carrier support for holding a carrier, wherein the carrier is configured to hold a plurality of receivers, and the carrier support is configured to be movable between a first position and a second position. The carrier support includes a carrier locking mechanism configured to lock the carrier to the carrier support when the carrier support is moved to the second position and to release the carrier when the carrier support is moved to the first position, thereby allowing the carrier to be moved relative to the carrier support when the carrier support is in the first position. The carrier locking mechanism includes a pivot latch configured to pivot between a first position not engaged with a portion of the carrier and a second position engaged with a portion of the carrier, and a sliding latch configured to translate linearly between a first position not engaged with a portion of the carrier and a second position engaged with a portion of the carrier.

[0040] In another embodiment, the carrier further comprises a torsion spring coupled to a pivot latch and biasing the pivot latch to a second position in which it engages with a portion of the carrier, and a linear spring coupled to a sliding latch and biasing the sliding latch to a second position in which it engages with a portion of the carrier.

[0041] In another embodiment, the pivot latch includes an upper end that engages with a portion of the carrier on the carrier support when the carrier support is in a second position and the pivot latch is in a second position, and a lower end that contacts a hard stop when the carrier support is moved from its second position to its first position, thereby rotating the pivot latch from the second position to the first position, thereby releasing the carrier supported on the carrier support. The sliding latch engages with a portion of the carrier on the carrier support when the carrier support is in a second position and the sliding latch is in a second position, and the sliding latch contacts a hard stop that pushes the sliding latch to the first position when the carrier support is moved from its second position to its first position, thereby releasing the carrier supported on the carrier support.

[0042] Aspects of the present disclosure are embodied in an input module comprising: a carrier shelf for receiving and supporting a carrier that holds a plurality of receivers; a recovery dock adjacent to the carrier shelf, configured to receive one receiver from a carrier supported on the carrier shelf and to provide the receiver for removal from an input module by a receiver transport device; and an extruder configured to push one or more receivers held on a carrier supported on the carrier shelf to one end of the carrier, and to push one receiver at a time from the end of the carrier into the recovery dock.

[0043] In another embodiment, the extruder comprises an extruder carriage coupled to an extruder track and configured to translate bidirectionally along the track, and an extruder arm protruding from the extruder carriage.

[0044] In another embodiment, the extruder arm comprises a support portion extending upward from the extruder carriage, a lateral portion extending laterally from the end of the support portion, and a contact portion extending downward from the lateral portion.

[0045] In another embodiment, a carrier supported on a carrier shelf includes a pair of parallel support rails for slidably supporting a plurality of receivers thereon, with at least a portion of each receiver positioned between the support rails, and a contact portion aligned with the gap between the support rails, so that as the extruder moves along the extruder track, the contact portion moves between the support rails and contacts a portion of the receiver positioned between the support rails.

[0046] In another embodiment, the receiver comprises a plurality of cylindrical tubes connected to one another by a connecting rib structure defining downward shoulders, at least one of the cylindrical tubes positioned between support rails, and a portion of the downward shoulders supported on the upper part of the support rails.

[0047] In another embodiment, the extruder further comprises an extruder drive belt attached to the extruder carriage, and an extruder motor coupled to the extruder drive belt for providing powered translation of the extruder carriage along the extruder track.

[0048] In another embodiment, the input module further comprises a sensor configured to detect when one of the receivers is pushed into the retrieval dock.

[0049] In another embodiment, the input module further comprises a guide plate adjacent to the recovery dock and configured to align the receiver on the recovery dock with the receiver transport device.

[0050] In another embodiment, the input module further comprises at least one carrier locator pin protruding from the carrier shelf to engage with an opening formed in a carrier supported by the carrier shelf and to restrict relative movement between the carrier shelf and the carrier supported by it.

[0051] In another embodiment, the input module further comprises a position encoder for detecting the longitudinal position of the extruder, and a control unit configured to receive longitudinal position data from the position encoder when the extruder is positioned in contact with the last end receiver of one or more receivers held on a carrier, and to determine the number of receivers supported by the carrier supported on a carrier shelf.

[0052] In another embodiment, the input module further comprises an extruder home sensor configured to detect when the extruder has moved to the home position.

[0053] In another embodiment, the processing equipment comprises an input module as described above, and a receiver transport device configured to retrieve a receiver from the input module's retrieval dock and transport the receiver within the processing equipment.

[0054] An aspect of the present disclosure is embodied in a carrier for holding a plurality of multiple receiver units, each multiple receiver unit comprising a plurality of receivers arranged in parallel and connected to one another. The carrier comprises a pair of parallel support rails for slidably supporting the multiple receiver units thereon, the pair of parallel support rails with at least one receiver of each multiple receiver unit positioned between the support rails, and elastic tabs associated with each support rail and configured to releasably hold the multiple receiver units held on the support rails.

[0055] In another embodiment, each elastic tab is positioned at the end of the meandering spring.

[0056] In another embodiment, each serpentine spring is an integral part of each associated support rail.

[0057] In another embodiment, the support rail is made of spring steel.

[0058] In another embodiment, the carrier further comprises a carrier base having a first end, a second end, and a connecting portion extending between the first end and the second end, the connecting portion being typically narrower than the first end and the second end.

[0059] In another embodiment, the support rail is attached to the opposing edges of the connecting portion.

[0060] In another embodiment, the carrier further comprises a carrier base having one or more locator holes formed at the bottom of the carrier base.

[0061] In another embodiment, the carrier further comprises a locator hole at a first end of the carrier base and a locator slot at a second end of the carrier base.

[0062] In another embodiment, the carrier further comprises two locator holes at a first end of the carrier base and two locator slots at a second end of the carrier base.

[0063] An aspect of the present disclosure is embodied in a scissors actuator configured to translate a support frame in either a lateral direction opposite to a base frame. The scissors actuator comprises a first arm having a first end and a second end, and a second arm having a first end and a second end, wherein the first arm and the second arm are rotatably connected to each other at an intermediate position between their respective first and second ends, the first arm being pivotably attached at its first end to the base frame and the second arm, and at its second end to the support frame, and the first sliding body being positioned within a first linear track formed in the support frame and on the support frame The first sliding body includes a bearing that protrudes from the side of the first sliding body to make rolling contact with the side of the first linear track formed thereon, the first arm is pivotably and translatably mounted to a support frame by the first sliding body at its second end, the second sliding body is positioned in a second linear track formed in the base frame and includes a bearing that protrudes from the side of the second sliding body to make rolling contact with the side of the second linear track surface formed in the base frame, the second arm is pivotably and translatably mounted to the base frame by the second sliding body at its first end.

[0064] In another embodiment, a first arm and a second arm are rotatably connected to each other by a swivel ring having an inner ring and an outer ring, the inner ring and the outer ring being rotatable relative to each other, the first arm being attached to the inner ring at its respective intermediate position, and the second arm being attached to the outer ring at its respective intermediate position.

[0065] In another embodiment, the scissors actuator further comprises a motor coupled to the first end of the first arm, which provides a pivotal motion of the first arm powered by the motor.

[0066] In another embodiment, the scissors actuator further comprises an encoder coupled to a motor or to a first arm.

[0067] In another embodiment, the scissors actuator is configured to translate the support frame in one of two opposing lateral directions relative to the base frame.

[0068] Aspects of the present disclosure are embodied in a method for automatically transferring a receiver between a holding shelf and a lift stand of a conveyor. The method includes the steps of: a) positioning a conveyor at an approximate vertical position of the holding shelf by a conveyor lift to cause vertical movement of the conveyor; b) causing relative movement between the lift stand and a positioning structure associated with the holding shelf after step a); c) detecting contact between the lift stand and the positioning structure during step b); d) recording data relating to the position of the lift stand where contact is detected in step c); and e) transferring a receiver between the holding shelf and the lift stand by controlling the movement of the lift stand in accordance with the data recorded in step d).

[0069] In another embodiment, step b) includes (1) causing vertical movement of the lift base relative to the holding shelf by a conveyor lifter, and (2) causing lateral movement of the lift base by a lateral actuator, or both.

[0070] In another embodiment, step a) includes positioning the conveyor such that the vertical position of the lift stand is below the expected vertical position of the positioning structure, and step b) includes b-1) moving the lift stand laterally with a lateral actuator until the lift stand is positioned below the expected position of the positioning structure, and b-2) after step b-1) raising the conveyor and lift stand with a conveyor lift until contact is detected in step c).

[0071] In another embodiment, step a) includes positioning the conveyor such that the vertical position of the lift stand is above the expected vertical position of the positioning structure, and step b) includes b-1) moving the lift stand laterally with a lateral actuator until the lift stand is positioned above the expected position of the positioning structure, and b-2) after step b-1) lowering the conveyor and lift stand with a conveyor lift until contact is detected in step c).

[0072] In another embodiment, step a) includes positioning the conveyor such that the vertical position of the lift base is the same as the expected vertical position of the positioning structure, and step b) includes moving the lift base laterally by a lateral actuator until contact is detected in step c).

[0073] In another embodiment, step e) includes supporting the receiver on the lift stand such that opposing ends of the receiver extend beyond the opposing ends of the lift stand; positioning the conveyor vertically so that the lift stand is above the holding shelf using the conveyor lift and the data recorded in step d); causing the lift stand to move laterally using the lateral actuator and the data recorded in step d) so that the lift stand is positioned within the open area between the first and second shelf portions of the holding shelf and the opposing ends of the receiver are positioned above the first and second shelf portions; and lowering the lift stand using the conveyor lift until the opposing ends of the receiver are supported above the first and second shelf portions and the receiver is no longer supported on the lift stand.

[0074] In another embodiment, step e) includes transferring the receiver carrier from the holding shelf to the lift stand by supporting the opposing ends of the receiver carrier on the first and second shelf portions of the holding shelf; positioning the conveyor vertically so that the lift stand is below the holding shelf by the conveyor lift and using the data recorded in step d); causing the lift stand to move laterally by the lateral actuator and using the data recorded in step d) so that the lift stand is aligned with the open area between the first and second shelf portions; and raising the lift stand by the conveyor lift until the opposing ends of the receiver carrier extend beyond the opposing ends of the lift stand and the opposing ends of the receiver carrier are lifted away from the first and second shelf portions.

[0075] Aspects of the present disclosure are embodied in a method for determining the number of receivers supported by a carrier. The method includes: a) arranging carriers supported by one or more receivers on a carrier shelf; b) pushing one or more receivers onto one end of the carrier by a packaging machine positioned adjacent to the carrier shelf; c) detecting the longitudinal position of the packaging machine when one or more receivers have been pushed onto one end of the carrier; and d) determining the number of receivers held on the carrier based on the longitudinal position of the packaging machine.

[0076] In another embodiment, step a) includes: transferring a carrier from a lift stand to a carrier shelf by supporting the carrier on the lift stand such that opposing ends of the carrier extend beyond the opposing ends of the lift stand; positioning the lift stand on the carrier shelf using a transport lift; causing lateral movement of the lift stand by a lateral actuator so that the lift stand is positioned in an open area between a first shelf portion and a second shelf portion of the carrier shelf and opposing ends of the carrier are positioned on the first shelf and the second shelf portion; and lowering the lift stand using a transport lift until opposing ends of the carrier are supported on the first shelf portion and the second shelf portion and the carrier is no longer supported on the lift stand.

[0077] In another embodiment, the packaging machine comprises a packaging machine carriage coupled to a packaging machine track and configured to translate bidirectionally along the track; a contact portion protruding from the packaging machine carriage; a packaging machine drive belt attached to the packaging machine carriage; and a packaging machine motor coupled to the packaging machine drive belt for providing powered translation of the packaging machine carriage along the packaging machine track.

[0078] In another embodiment, step c) includes detecting the output of the packaging machine motor by a rotary encoder coupled to the packaging machine motor, or by detecting the output of the packaging machine motor by a motor step.

[0079] Aspects of the present disclosure are embodied in a method for packaging a plurality of receivers supported by a carrier. The method includes: a) arranging a carrier on a carrier shelf in which a plurality of receivers are supported; b) bringing one of the final ends of the receivers into contact with a packaging machine positioned adjacent to the carrier shelf, the packaging machine comprising a packaging machine carriage coupled to a packaging machine track and configured to translate bidirectionally along the track, with a contact portion protruding from the packaging machine carriage; and c) pushing the plurality of receivers into one end of the carrier with the packaging machine, thereby packaging the receivers in a stack.

[0080] In another embodiment, a carrier supported on a carrier shelf includes a pair of parallel support rails for slidably supporting a plurality of receivers thereon, with at least a portion of each receiver positioned between the support rails, and step c) includes bringing a baler into contact with one of the end ends of the receivers by aligning a contact portion in the gap between the support rails, so that as the baler carriage translates along the baler track, the contact portion moves between the support rails and contacts the portion of the end receiver positioned between the support rails.

[0081] In another embodiment, the carrier includes hard stops at the ends of each support rail, and step c) includes pushing a plurality of receivers against the hard stops.

[0082] In another embodiment, the receiver comprises a plurality of cylindrical tubes connected to one another by a connecting rib structure defining downward shoulders, at least one of the cylindrical tubes positioned between support rails, and a portion of the downward shoulders supported on the upper part of the support rails.

[0083] In another embodiment, the packaging machine further comprises a horizontal portion that contacts a portion of the final end receiver extending over a support rail, thereby keeping the receiver generally perpendicular to the longitudinal direction of the support rail.

[0084] In another embodiment, the packaging machine further comprises a packaging machine drive belt attached to the packaging machine carriage, and a packaging machine motor coupled to the packaging machine drive belt for providing powered translation of the packaging machine carriage along the packaging machine track.

[0085] In another embodiment, the method further includes detecting the longitudinal position of the packaging machine during step c) and determining the number of receivers held on the carrier based on the longitudinal position of the packaging machine.

[0086] In another embodiment, the packaging machine further comprises a packaging machine drive belt attached to a packaging machine carriage and a packaging machine motor coupled to the packaging machine drive belt for powered translation of the packaging machine carriage along a packaging machine trajectory, and includes detecting the initial position of the packaging machine along the packaging machine trajectory using a home sensor during step c), and detecting the number of encoder counts associated with the movement of the electric packaging machine from the initial position using an encoder coupled to the packaging machine motor.

[0087] Aspects of the present disclosure are embodied in a method for providing multiple receiver units for retrieval by an automatic receiver distributor of processing equipment, each multiple receiver unit comprising a plurality of receivers arranged in parallel and connected to one another, the method comprising: a) arranging one or more multiple receiver units on a carrier shelf, the carrier comprising a pair of parallel support rails for slidably supporting multiple receiver units thereon, and at least one of the receivers of each multiple receiver unit being arranged between the support rails; b) bringing one of the final ends of the receivers into contact with an extruder positioned adjacent to the carrier shelf, the extruder being configured to move between the support rails and make contact with receivers positioned between the support rails; and c) pushing the plurality of multiple receiver units along the support rails toward one end of the carrier by the extruder until one of the final ends of the multiple receiver units is pushed out from the support rails and pushed into a retrieval dock adjacent to the carrier shelf.

[0088] In another embodiment, the method further includes detecting that one of a plurality of multiple receiver units has been pushed out of the support rail and into the recovery dock, and stopping the extruder from further pushing one or more multiple receiver units toward one end of the transport body.

[0089] In another embodiment, the method further includes retrieving a single multi-receiving unit from a retrieval dock by a receiver transport mechanism of a processing device.

[0090] In another embodiment, the receiver transport mechanism comprises an extendable hook, and the multiple receiver unit comprises an operating structure, and retrieving one receiver from a retrieval dock equipped with the receiver transport mechanism comprises extending the hook, engaging the operating structure with the extended hook, and retracting the hook to pull the multiple receiver unit from the retrieval dock into the housing of the receiver transport mechanism.

[0091] In another embodiment, the method further includes, during step c), detecting the longitudinal position of the extruder when the multiple receiver units are pushed out from the support rail, and determining the number of multiple receiver units held on the carrier based on the longitudinal position of the extruder.

[0092] In another embodiment, step a) includes: transferring a carrier from a lift stand to a carrier shelf by supporting the carrier on the lift stand such that opposing ends of the carrier extend beyond the opposing ends of the lift stand; positioning the lift stand on the carrier shelf using a transport lift; causing lateral movement of the lift stand by a lateral actuator so that the lift stand is positioned in an open area between a first shelf portion and a second shelf portion of the carrier shelf and opposing ends of the carrier are positioned on the first shelf and the second shelf portion; and lowering the lift stand using a transport lift until opposing ends of the carrier are supported on the first shelf portion and the second shelf portion and the carrier is no longer supported on the lift stand.

[0093] In another embodiment, the extruder further comprises an extruder carriage coupled to an extruder track and configured to translate bidirectionally along the track; an extruder arm having a contact portion and protruding from the extruder carriage; an extruder drive belt attached to the extruder carriage; and an extruder motor coupled to the extruder drive belt for powered translation of the extruder carriage along the extruder track.

[0094] In another embodiment, the method further includes, prior to step c), holding one or more multiple receiver units on a support rail by a spring-biased retaining tab that releasably engages with one of the furthest ends of the multiple receiver units, wherein the spring-biased retaining tab is configured to deflect laterally during step c) to allow one of the final ends of the multiple receiver units to be pushed off the support rail.

[0095] Other features and characteristics of the subject matter of this disclosure, as well as the methods of operation, the functions and combinations of components of the relevant structural elements, and the economics of manufacture, will become more apparent from the following description and the attached claims with reference to the attached drawings. All of these attached drawings form part of this specification, and reference numbers, for example, indicate corresponding parts in various figures. The present invention provides, for example, the following: (Item 1) A device for transporting a collection of consumables between multiple vertically spaced holding shelves, A support chassis positioned laterally spaced apart from the plurality of holding shelves, A transport elevator coupled to the support chassis for moving the support chassis vertically between the plurality of holding shelves, Lift platform and The apparatus comprises a lift frame connected to the support chassis, and a scissors actuator configured to laterally translate the lift frame relative to the support chassis between a first position where the lift frame is laterally spaced apart from the plurality of holding shelves and laterally aligned with the support chassis, and a second position where the lift frame is laterally displaced from the support chassis and laterally aligned with one of the holding shelves. (Item 2) It is a device, Multiple vertically spaced holding shelves, A conveying machine for transporting an assembly of consumables between the plurality of holding shelves, A support chassis positioned laterally spaced apart from the plurality of holding shelves, Lift platform and A conveyor comprising: a lift frame connected to the support chassis; a scissors actuator configured to laterally translate the lift frame relative to the support chassis between a first position where the lift frame is laterally spaced apart from the plurality of holding shelves and laterally aligned with the support chassis; and a second position where the lift frame is laterally displaced from the support chassis and laterally aligned with one of the holding shelves; An apparatus comprising a transport elevator coupled to the support chassis for moving the support chassis vertically between the plurality of holding shelves. (Item 3) A carrier support for holding a carrier, wherein the carrier is configured to hold a plurality of receivers, the carrier support is configured to be movable between a first position and a second position, and the carrier support comprises a carrier locking mechanism configured to lock the carrier to the carrier support when the carrier support moves to the second position, release the carrier when the carrier support moves to the first position, and move the carrier relative to the carrier support when the carrier support is in the first position, and the carrier locking mechanism is configured A pivot latch configured to pivot between a first position in which it does not engage with a portion of the transport body and a second position in which it engages with a portion of the transport body, A carrier support comprising a sliding latch configured to translate linearly between a first position in which it does not engage with a portion of the carrier and a second position in which it engages with a portion of the carrier. (Item 4) An input module, A carrier shelf for receiving and supporting a carrier that holds multiple receivers, A recovery dock is provided adjacent to the transport shelf and configured to receive one receiver from a transport body supported on the transport shelf, and to provide the receiver for retrieval from the input module by a receiver transport device. An input module comprising: an extruder configured to push one or more receivers held on the carrier supported on the carrier shelf toward one end of the carrier, and to push one receiver at a time out of the end of the carrier toward the recovery dock. (Item 5) A carrier for holding multiple multiple receiver units, wherein each multiple receiver unit includes multiple receivers arranged in parallel and connected to each other, and the carrier is A pair of parallel support rails for slidably supporting the multi-receiver unit located thereon, wherein at least one of the receivers of each multi-receiver unit is positioned between the support rails; A carrier comprising: elastic tabs associated with each support rail and configured to releasably hold the multiple receiver unit on the support rail. (Item 6) A scissors actuator configured to translate a support frame in either the lateral direction opposite to the base frame, A first arm having a first end and a second end, A second arm having a first end and a second end, wherein the first arm and the second arm are rotatably connected to each other at an intermediate position between their respective first and second ends, and the first arm is pivotably attached at its first end to the base frame and the second arm, and at its second end to the support frame, A first sliding body, which is positioned within a first linear track formed in the support frame, and includes a bearing protruding from the side of the first sliding body so as to make rolling contact with the side of the first linear track formed in the support frame, wherein the first arm is pivotably and translatably attached to the support frame by the first sliding body at its second end, A scissors actuator comprising: a second sliding body, which is disposed within a second linear track formed in the base frame and includes a bearing protruding from the side of the second sliding body so as to make rolling contact with the side of the second linear track formed in the base frame, wherein the second arm is pivotably and translationally attached to the base frame by the second sliding body at its first end. (Item 7) A method for automatically transferring a receiving container between a holding shelf and a lift frame of a conveyor, a) Positioning the conveyor at an approximate vertical position on the holding shelf by a conveyor lifting mechanism that brings about the vertical movement of the conveyor, b) After step a), a relative movement is brought about between the lift frame and the positioning structure associated with the holding shelf, c) During step b), contact between the lift frame and the positioning structure is detected, d) Record data relating to the position of the lift platform where contact was detected in step c), e) A method comprising transferring a receiver between the holding shelf and the lift stand by controlling the movement of the lift stand in accordance with the data recorded in step d). (Item 8) A method for determining the number of receivers supported by a carrier, a) Arranging the transporter, which supports one or more receivers, on a transporter shelf, b) A packaging machine positioned adjacent to the transport shelf pushes one or more receivers onto one end of the transport body, c) When one or more receivers are pressed into one end of the transport body, the longitudinal position of the packaging machine is detected, d) A method comprising determining the number of receivers held on the carrier based on the longitudinal position of the packaging machine. (Item 9) A method for packaging multiple receivers supported by a carrier, a) thereby arranging the transporter, which supports multiple receivers, on a transporter shelf, b) Contacting one of the rearmost ends of the receivers with a packaging machine positioned adjacent to the transport shelf, wherein the packaging machine comprises a packaging machine carriage connected to a packaging machine track and configured to translate bidirectionally along the track, and the contact portion protrudes from the packaging machine carriage. c) A method comprising pushing the plurality of receivers onto one end of the transport body using the packaging machine, thereby loading the receivers into the stack section. (Item 10) A method for providing a multiple receiver unit for collection by an automatic receiver distributor of processing equipment, wherein each multiple receiver unit includes a plurality of receivers arranged in parallel and connected to each other. a) Arranging carriers on a carrier shelf, each having one or more multi-receiver units holding a carrier thereon, wherein the carriers are provided with a pair of parallel support rails for slidably supporting the multi-receiver units thereon, and at least one of the receivers of each multi-receiver unit is positioned between the support rails. b) Contacting one of the final ends of the receiver with an extruder positioned adjacent to the transport shelf, wherein the extruder has a contact portion configured to move between the support rails and contact the receiver positioned between the support rails, c) A method comprising using an extruder to push the multiple receiving units along the support rail toward one end of the transport body until one of the final ends of the multiple receiving units is pushed out from the support rail and pushed into a retrieval dock adjacent to the transport body shelf. [Brief explanation of the drawing]

[0096] The accompanying drawings, incorporated herein and forming part of the specification, illustrate various non-limiting embodiments of this disclosure. In the drawings, similar reference numerals indicate identical or functionally similar elements.

[0097] [Figure 1] This is a plan view of a system for transporting and holding consumables, comprising a transporter / storage module and an input module disclosed herein, combined with processing equipment for performing chemical, biological, or other multi-stage analytical processes. [Figure 2] This is a perspective view of a transporter / storage module according to an embodiment of the present disclosure. [Figure 3] This is a side view of the conveyor / storage module. [Figure 4]This is a partial perspective view of the transport / storage module with the access door in the open position and the loading drawer partially pulled out from the module's housing. [Figure 4A] This is a top view of a holding shelf with a lift frame positioned within the open area of ​​the holding shelf. [Figure 5] This is a partial perspective view of the upper end of the transport / storage module with the access door in the closed position and the loading drawer inserted into the housing. [Figure 6] This is a partial side view of the transport / storage module with the access door in the closed position and the loading drawer inserted into the housing. [Figure 7] This is a partial perspective view of a loading drawer inserted into a housing with a transporter placed inside, showing the receiving and packaging mechanism. [Figure 7A] Figure 7 shows an end view in the direction of arrow "7A," illustrating the packaging machine of the receiving packaging mechanism separated within the linear track. [Figure 8] This is a perspective view of the loading drawer removed from the module housing. [Figure 9] This is a perspective view of a type of multiple receiver unit that is transported and stored, according to an embodiment of the system. [Figure 10] This is a top view of a transporter for transporting and storing consumables within a system. [Figure 11] This is a bottom perspective view of the transport vehicle. [Figure 12] This is a partial perspective view of an alternative embodiment of the transporter. [Figure 13] This is a top perspective view of a transporter with multiple multi-receiving units supported on top. [Figure 14] This is a bottom perspective view of a transporter with multiple multi-receiving units supported on top. [Figure 15] This is a top perspective view of the conveyor / storage module conveyor with the lift base in the retracted position. [Figure 16] This is a top perspective view of the conveyor with the lift stand extending from one side of the conveyor. [Figure 17] This is an exploded perspective view of the conveyor with the lift stand extending to one side of the conveyor. [Figure 18] This is a top perspective view of the conveyor with the lift frame extending to the opposing sides of the conveyor. [Figure 19] This is a bottom perspective view of the conveyor with the lift stand extending to the opposing sides of the conveyor. [Figure 20] This is a top perspective view of a conveyor with a lift stand extending from one side of the conveyor and the transported object supported by the lift stand. [Figure 21] This is a perspective view of the system's transport and lifting mechanism. [Figure 22] This is a front right-side perspective view of the input module of a system for transferring consumables from a conveyor / storage module to processing equipment. [Figure 23] This is a rear right-side perspective view of the input module. [Figure 24] This is a front right-side perspective view of the input module, showing the carrier supporting multiple multiple receiver units positioned within the queue. [Figure 25] This is a front left perspective view of the input module, showing the receiver distribution head of the receiver distributor of the processing equipment extending a multiple receiver unit from the input module (some components are omitted in this diagram to ensure visibility of related mechanisms). [Figure 26] This is a partial perspective view of a conveyor, showing sensors used to detect the presence of a transported object on the conveyor. [Figure 27] This flowchart shows a method (algorithm) for performing an auto-correction process to determine the position within a transporter / storage module and / or input module. [Figure 28] This is a block diagram illustrating the control architecture of the transporter / storage module. [Modes for carrying out the invention]

[0098] While aspects of the subject matter of this disclosure can be embodied in various forms, the following description and accompanying drawings are intended only to disclose some of these forms as specific examples of the subject matter. Therefore, the subject matter of this disclosure is not intended to be limited to the forms or embodiments described and illustrated in this manner.

[0099] Unless otherwise defined, all technical terms, notations, and other scientific or specialized terms used herein have the same meaning as those generally understood by those skilled in the art to which this disclosure belongs. All patents, uses, published applications, and other publications referenced herein are incorporated as a whole by reference. If any definition in this section contradicts or is inconsistent with any definition in a patent, application, published application, or other publication incorporated herein by reference, the definition in this section shall prevail over the definition incorporated herein by reference.

[0100] As used herein, "a" or "an" means "at least one" or "one or more."

[0101] This description may use relative spatial and / or orientation terms when describing the location and / or orientation of components, devices, locations, features, or parts thereof. Unless otherwise specified or indicated by the context of the description, such terms, including but not limited to, top, bottom, above, below, upside, downside, left, right, front, back, adjacent, between, horizontal, vertical, diagonal, longitudinal, transverse, radial, axial, etc., are used for convenience when referring to such components, devices, locations, features, or parts thereof in drawings, but are not intended to be limiting.

[0102] Furthermore, unless otherwise specified, the specific dimensions mentioned in this description represent, and are not intended to be limiting, exemplary implementations of devices embodying aspects of this disclosure.

[0103] The use of the term "about" applies to all numerical values ​​specified herein, whether expressly indicated or not. This term refers to a range of numerical values ​​that a person skilled in the art would typically consider to be a reasonable deviation from the numerical values ​​enumerated in the context of this disclosure (i.e., having a function or result such as the same). For example, though not intended to be limiting, this term could be interpreted to include deviations of ±10 percent from a given numerical value, but such deviations would not alter the final function or result of the value. Thus, under certain circumstances as understood by a person skilled in the art, a value of about 1 percent could be interpreted as ranging from 0.9% to 1.1%.

[0104] As used herein, the term “adjacent” means being close or adjacent. Adjacent objects can be separated from each other or can actually be in direct contact with each other. In some cases, adjacent objects can be joined together or can form a single unit with each other.

[0105] As used herein, the terms “substantial” and “substantially” refer to a considerable degree or extent. When used in conjunction with events, situations, characteristics, or properties, these terms may refer to instances in which the event, situation, characteristic, or property occurs exactly, and instances in which the event, situation, characteristic, or property occurs with a strict approximation, such as when describing the typical tolerance level or variability of the embodiments described herein.

[0106] As used herein, the terms “optional” and “optionally” mean that the components, structures, elements, events, situations, characteristics, traits, etc. described thereafter may or may not be included, or may occur, and that such descriptions may or may not include, or occur, the components, structural elements, events, situations, characteristics, traits, etc.

[0107] Systems and methods for transporting and holding consumables within a processing instrument are described herein. The processing instrument may be an analyzer for performing biological, chemical, biochemical, or other multi-step analytical processes, and the consumables may comprise receivers in which such processes are performed within the analyzer. As shown in Figure 1, embodiments of the systems and methods may include one or both of a transporter / storage module 100 for transporting and holding a supply of consumables to be supplied to a processing instrument 400, and an input module 230 configured to receive consumables from the transporter / storage module 100 and provide the consumables for input to the processing instrument 400 by a distribution mechanism within the processing instrument 400. Further details of an exemplary processing instrument 400 are described below.

[0108] Details of various configurations of the transporter / storage module 100 are shown in Figures 2 to 8.

[0109] Figure 2 is a perspective view of a conveyor / storage module 100 for transporting and holding a supply of consumables provided to processing equipment, in which the consumables are moved, processed, or otherwise handled. Figure 3 is a side view of the conveyor / storage module, and Figure 6 is a partial side view of the conveyor / storage module. The conveyor / storage module 100 includes a housing 102 and one or more vertically spaced holding shelves 104. An access door 106 is opened to allow a loading drawer 280 to be pulled out of the housing 102, and as a result, multiple consumables can be provided to the conveyor / storage module 100 by arranging them on and then inserting the loading drawer 280 into the housing 102. The consumables may be supported on a carrier configured to be supported on either the loading drawer 280 or the holding shelves 104.

[0110] The conveyor 120 is configured to remove consumables from one of the loading drawers 280 or the holding shelf 104, for example, by removing a carrier supporting the consumables from either the loading drawer 280 or the holding shelf 104. The conveyor 120 is further configured to move an assembly of consumables, such as a carrier supporting the consumables or an empty carrier, to either the loading drawer 280 or one of the holding shelves 104. A vertical conveying mechanism is coupled to the conveyor 120 and is configured to move the conveyor 120 vertically (up or down) between the loading drawer 280 and the holding shelf 104. In one embodiment, the vertical conveying mechanism comprises the conveyor 120 and a conveying lifter 210 that moves the consumables (and carriers) supported thereon vertically within the housing 102.

[0111] The input module 230 is configured to receive consumables (e.g., consumables supported on a carrier) that are transported into the input module 230 from one of the holding shelves 104 by the conveyor 120. In embodiments, the input module 230 may be incorporated into the housing of a processing machine. From the input module 230, the consumables are selectively collected into the processing machine 400 and moved or otherwise manipulated within the processing machine. After all consumables have been removed from the carriers in the input module 230, the conveyor 120 will move the empty carrier from the input module 230 to either the loading drawer 280 or one of the holding shelves 104. Further details of the input module 230 are described below.

[0112] The relative positions of the conveyor / storage module 100, the conveyor 120, the loading drawer 280 and the holding shelf 104, and the input module 230 relative to the processing equipment 400 are schematically shown by dashed lines in Figure 1. These relative positions are illustrative and not intended to be limiting.

[0113] As shown in Figure 1, the processing instrument 400 may include various modules configured to receive one or more receptors (their embodiments are described in more detail below), in each of which one or more steps of a biological, chemical, biochemical, or other multi-step analytical process may be performed. The modules of the processing instrument 400 constitute receptor-receiving structures configured to receive and hold one or more receptors.

[0114] The processing apparatus 400 may further include loading stations 404, 406, 408 configured to receive receivers, in which one or more materials can be added to the receivers by an automated pipette (not shown) containing, for example, sample materials and various reaction reagents.

[0115] The processing apparatus 400 may further comprise one or more integrating stations 410 for holding a receiver containing a reaction mixture before subsequent processing in another module of the processing apparatus 400. The integrating station 410 may include magnets for attracting a magnetically responsive solid support to the inner wall of the receiver, thereby pulling the solid support away from the suspension. An exemplary integrating station is described in U.S. Patent No. 8,276,762.

[0116] The processing apparatus 400 may include one or more incubators 412, 414, 416 configured to receive multiple receivers and heat (and / or maintain) the contents of the receivers at a temperature higher than the ambient temperature. The illustrated embodiment includes three incubators 412, 414, 416, each of which may be configured to heat and / or maintain the contents of receivers at different temperatures. Exemplary incubators are described in U.S. Patents 7,964,413 and 8,718,948.

[0117] The processing instrument 400 may include sample processing devices such as magnetic washing stations 418, 420 adapted to separate or isolate target nucleic acids or other specimens (e.g., immobilized on a magnetically responsive solid support) from the remaining contents of a receiver. Exemplary magnetic washing stations are described in U.S. Patents 6,605,213 and 9,011,771.

[0118] The processing instrument 400 may further include a detector 424 configured to receive a receiver and detect a signal (e.g., a light signal such as fluorescence or chemiluminescence) emitted by the contents of the receiver. In one embodiment, the detector 424 may include an illuminometer for detecting a light emission signal emitted by the contents of the receiver and / or a fluorometer for detecting fluorescence emission from the contents of the receiver. The processing instrument 400 may also include one or more signal detection devices, such as a fluorometer (e.g., connected to one or more incubators 412, 414, 416), configured to detect (e.g., at periodic intervals) a signal emitted by the contents of a receiver contained in an incubator while a process such as nucleic acid amplification is taking place in a reaction vessel. Exemplary illuminometers and fluorometers are described in U.S. Patents No. 7,396,509 and No. 8,008,066.

[0119] The processing equipment 400 further includes a receiver transport device, and in the illustrated embodiment, a receiver distributor 430. Each module of the processing equipment 400 includes a receiver transport portal into which receivers are inserted or removed from which receivers are removed. Each module may or may not include an openable door covering the receiver portal. The receiver distributor 430 is configured to move receivers between different modules, retrieve receivers from modules, and deposit receivers into modules. More specifically, the receiver distributor 430 includes a receiver distribution head 432 configured to move in the X direction along a transport track 434, rotate in the theta (Θ) direction, and move receivers in the R direction between the receiver distribution head 432 and one of the modules of the processing equipment 400. The receiver distributor 430 may be further configured to remove receivers one at a time from the input module 230 described herein.

[0120] During operation, the receiver distribution head 432 moves along the transport track 434 in the X direction to a transport position for one of the modules, i.e., the input module 230. The distribution head then rotates in the Θ direction to align the distribution head with respect to the receiver transport portal of the module, i.e., the input module 230, in the receiver transport direction. A receiver movement mechanism, such as a linear actuation hook, moves in the R direction relative to the distribution head 432 to move a receiver from the distribution head 432 to the module, or to retrieve a receiver from the module, i.e., the input module 230, into the distribution head 432. In embodiments, the receiver distributor 430 further includes means for providing vertical (Z-axis, orthogonal to the page in Figure 1) position adjustment of the distribution head 432 to accommodate variations in the vertical position of the receiver transport portals of various modules. The receiver distributor 430 may include structural elements and associated control logic for opening doors covering the receiver transport portals before inserting a receiver into a module or before removing a receiver from a module.

[0121] An exemplary receiver transport device, an exemplary receiver transport portal door, and a mechanism for opening the door are described in U.S. Patent No. 8,731,712.

[0122] Exemplary processing equipment in which the conveyor / storage module 100 may be used includes analyzers described in U.S. Patent Nos. 8,731,712 and 9,732,374 and International Patent Application No. PCT / US2018 / 041472, as well as the Panther® and Panther Fusion® systems available from Hologic, Inc. (Marlborough, MA).

[0123] Exemplary consumables that may be transported and stored within module 100 and supplied to processing equipment by input module 230 may include receivers for holding large quantities of material, such as the multiple receiver unit 160 shown in Figure 9. As shown in Figure 9, the multiple receiver unit ("MRU") 160 comprises a number of individual receivers 162 (five in the illustrated embodiment). In alternative embodiments, the MRU may include more or fewer than five receivers 162. In the illustrated example, the receivers 162 are in the form of cylindrical tubes (e.g., test tubes) with open upper and closed lower ends and are connected to each other by connecting rib structures 164 that define downward shoulders extending longitudinally along either side of the MRU 160. In other embodiments, receivers having configurations other than cylindrical tubes are contemplated. The receivers may be identical or different in size and / or shape.

[0124] In this embodiment, a curved shield structure 169 is provided at one end of the MRU 160. The MRU operating structure 166 extends from the shield structure 169. The operating structure is adapted to engage with a receiver distributor of the processing equipment, such as a receiver distributor 430 of the processing equipment 400, in order to pull the MRU 160 out of the input module 230 and to move the MRU 160 between different locations of the processing equipment 400. The MRU operating structure 166 comprises a laterally extending plate 168 extending from the shield structure 169 and a vertically extending piece 167 at the opposing end of the plate 168. A gusset wall 165 extends downward from the laterally extending plate 168 between the shield structure 169 and the vertical piece 167.

[0125] The shield structure 169 and the vertical piece 167 have convex surfaces facing the phase. The MRU 160 can be engaged by a distributor (e.g., distributor 430) by moving an engaging member (e.g., a hook) laterally within the space between the shield structure 169 and the vertical piece 167. The convex surfaces of the shield structure 169 and the vertical piece 167 provide a wider entry point for the engaging member moving laterally within the space.

[0126] A label receiving structure 174 having a flat label receiving surface 175 is provided at the end of the MRU 160 opposite the shield structure 169 and the MRU operating structure 166. The MRU 160 may also include a tiplet retaining structure 176 adjacent to the opening of each of the receivers 162. Each tiplet retaining structure 176 provides a cylindrical orifice into which a conduit, such as a contact-limiting tiplet 170, is received, which is adapted to be arranged on the end of a suction tube (not shown). An exemplary multiple receiver unit is described in U.S. Patent No. 6,086,827.

[0127] Transporter A carrier for holding consumables to be transported and stored in module 100 is indicated by reference numeral 300 in Figure 10, a top perspective view of the carrier 300, and in Figure 11, a bottom perspective view of the carrier 300. In one embodiment, the carrier 300 may comprise a type of rack including a carrier base 302 having a first end 304, a second end 306, and a connecting portion 308 extending between the first end 304 and the second end 306, which is typically narrower than the first end 304 and the second end 306.

[0128] A pair of parallel support rails 312, 314 extend substantially along the entire length of the transport base 302 and are attached to the transport base 302 by fasteners or fastening elements 324 that attach, for example, the support rails 312, 314 to the opposing edges of the connecting portion 308, thereby defining the distance between the support rails 312, 314 by the width of the connecting portion 308. The support rails 312, 314 and the transport base 302 can be made of any suitable material having sufficient strength and rigidity. Ideally, the transport body 300 is made of lightweight material to allow for rapid movement of the transport body. In one embodiment, the support rails 312, 314 are made from spring steel and the transport base 302 is made from aluminum. The fastening elements 324 may be welded or any suitable mechanical fastener, such as screws, rivets, or bolts, or a combination thereof.

[0129] As shown in Figure 11, the carrier base 302 includes a shell locator hole 340 and a lift base locator hole 344 formed at the bottom of the carrier base near the first end 304. The carrier base 302 further includes a lift base locator slot 346 and a shell locator slot 342 formed at the bottom of the carrier base adjacent to the second end 306.

[0130] The support rails 312 and 314 each include hard stop sections 316 and 318. In the illustrated embodiment, the hard stop sections 316 and 318 are equipped with stop flanges that extend laterally with respect to the support rails 312 and 314, and each hard stop section 316 and 318 is supported at its lower end by the second end 306 of the transport base 302 to provide lateral stability to the corresponding support rail.

[0131] Each support rail 312, 314 includes a retaining tab 320, 322, respectively. The retaining tab 320 is located at the end of the meandering spring 330, and the retaining tab 322 is located at the end of the meandering spring 332. The meandering springs 330, 332 allow for lateral bending of the retaining tabs 320, 322, respectively. In one embodiment, the springs 330, 332 are continuous with the support rails 312, 314 and are cut from the support rails 312, 314 (e.g., by laser cutting), and may be formed from spring steel as described above. In another embodiment (not shown), the retaining tabs 320, 322 may be located at the end of a meandering spring attached to the support rails 312, 314, but separate from them.

[0132] In the embodiment of rail 300 shown in Figures 10 and 11, tabs 320 and 322 are located below the ends 334 and 336 of support rails 312 and 314, respectively. In the alternative embodiment shown in Figure 12, the carrier 600 includes retaining tabs 620 and 622 at the ends of meandering springs 630 and 632, respectively, which are not located below support rails 612 and 614 but are longitudinally aligned with the ends 634 and 636, respectively. In other respects, the carrier 600 may be substantially identical to the carrier 300, and the carrier base 602 includes a first end 604 similar to the first end 304 and a connecting portion 608 similar to the connecting portion 308 to which support rails 612 and 614 are attached.

[0133] The carriers 300 shown in Figures 10 and 11, and the carrier 600 shown in Figure 12, are configured in particular to hold a plurality of MRUs 160s as shown in Figure 9, but other carrier configurations may be incorporated. Each MRU 160 is supported on the carrier 300 or 600 with an intermediate receiver 162 positioned between support rails 312, 314, or support rails 612, 614. A portion of the connecting rib structure 164 that connects the intermediate receiver 162 to an adjacent receiver on either side is supported on the upper edge of the support rails 312, 314, or support rails 612, 614.

[0134] Figures 13 and 14 are a top perspective view and a bottom perspective view, respectively, of the carrier 300 that holds multiple MRUs 160. As shown in Figures 13 and 14, when the carrier 300 is fully loaded with MRUs 160, the frontmost (leftmost in the figures) MRU 160 presses against the hard stoppers 316, 318, preventing the MRU from sliding off the left end of the support rails 312, 314. The retaining tabs 320, 322 are bent laterally outward, respectively, so that the tabs contact the receiver 162 on both sides of the central receiver located between the support rails 312, 314. Alternatively, the retaining tabs 320, 322 may be bent laterally inward so that the tabs contact the central receiver 162 located between the support rails 312, 314.

[0135] The retaining tabs 320 and 322 provide resistance to the final end (right end in the figure) MRU 160 sliding away from the right end of the support rails 312 and 314, for example, preventing the MRU 160 from "walking" away from the ends of the support rails 312 and 314 when horizontal due to ambient vibrations. Because the retaining tabs 320 and 322 are positioned at the ends of their respective serpentine springs 330 and 332, each tab can pivot inward if the retaining tab 320 and 322 is bent outward, and outward if the retaining tab 320 and 322 is bent inward, as a result the pressurizing force applied to the final end MRU 160, for example by pushing the entire stack of the MRU to the right, overcomes the resistance generated by the retaining tabs 320 and 322, thereby allowing the final end MRU 160 to be forcibly removed from the right end of the support rails 312 and 314.

[0136] The features of the retaining shelf 104 are shown in Figure 4A, which is a top view of the retaining shelf with the lift base positioned within the open area of ​​the retaining shelf. The retaining shelf 104 includes a first shelf portion 112 and a second shelf portion 114, with a connecting portion 118 extending between the first shelf portion 112 and the second shelf portion 114, and an open area 116 extending between the first shelf portion 112 and the second shelf portion 114. The retaining shelf positioning tab 108 extends laterally from the connecting portion 118. The first locator pin 110 protrudes above the first shelf portion 112, and the second locator pin 111 protrudes above the second shelf portion 114.

[0137] When the carrier 300 is supported on the holding shelf 104, the first locator pin 110 is received in the shelf locator hole 340 and the second locator pin 111 is received in the shelf locator slot 342. The locator pins 110, 111, and the shelf locator hole 340 and shelf locator slot 342 formed on the carrier base 302 facilitate the precise positioning of the carrier 300 on the holding shelf 104 and prevent lateral sliding of the carrier 300 within the holding shelf. To accommodate machining and manufacturing tolerances, the carrier 300 is positioned within the holding shelf 104 by the locator hole 340 at one end of the carrier 300 and the locator slot 342 at the other end of the carrier 300, and the elongated slot accommodates variations in the spacing between the first locator pin 110 and the second locator pin 111.

[0138] In alternative embodiments, locator pins may be provided on the carrier and locator holes may be provided on the holding shelf. For example, the carrier 300 may include locator pins projecting downward at the locations of a shelf locator hole 340 and a shelf locator slot 342, which engage with locator holes (e.g., one locator hole and one locator slot) formed in the holding shelf 104 at the locations of a first locator pin 110 and a second locator pin 111. In another embodiment, the carrier includes more or fewer locator holes / slots or locator pins that align with a corresponding number of locator pins or locator holes / slots on the holding shelf, respectively.

[0139] The holding shelf 104 may include sensors, such as the carrier detection sensor 115 shown in Figure 6, for detecting that the carrier 300 is positioned on the holding shelf 104. Details of an exemplary optical sensor are described below.

[0140] Loading drawer Various exemplary features of the loading drawer 280 are shown in Figures 5 to 8. The loading drawer 280, which can also function as a holding shelf for holding carriers 300, 600, is equipped with a support for the carriers, and may therefore also be called a carrier support, and is laterally movable relative to the housing 102 between a first position accessible by the conveyor 120 (shown in Figures 2, 3, 5, and 6) and a second position accessible by the user for loading multiple consumables into the drawer (shown in Figure 4, which is a partial perspective view of the conveyor / storage module 100 with the access door 106 in the open position and the loading drawer 280 partially pulled out from the housing 102 of module 100). The loading drawer 280 may be supported within the housing 102 on a linear track 281 (see Figure 7), such as a linear bearing, allowing the loading drawer 280 to move between the first position (also called the closed position) and the second position (also called the closed position). A sensor 299 (see Figures 5 and 7), which may include an optical sensor within the housing 102, may be provided to detect that the loading drawer 280 is in the closed position inserted into the housing 102.

[0141] The features of the loading drawer 280 are shown in Figure 8. The loading drawer 280 includes a side wall 284 that extends substantially the entire length of the drawer, a handle 282, a first shelf 286, and a second shelf 292, with an open space 298 between the first shelf 286 and the second shelf 292. A pair of stoppers 283 extend over the first shelf 286 to prevent any MRU 160 from falling from the end of the carrier 300 (or 600) supported on the loading drawer 280, in particular when the loading drawer 280 moves from an open position to a closed position, or when a user is loading an MRU 160 into the carrier. A first locator pin 288 protrudes above the first shelf 286, and a second locator pin 294 protrudes above the second shelf 292. The first shelf 286 includes a pivot latch 290, and the second shelf 292 includes a sliding latch 296. The loading drawer 280 is supported within the module housing 102 by one or more sliding bodies, tracks (such as a linear track 281), rolling bodies, or a combination thereof, for the sliding movement of the loading shelf 280 in and out of the access port formed in the module housing 102 at the access door 106. The loading drawer positioning tab 276 extends laterally from the housing 102 at a position adjacent to the loading drawer 280.

[0142] The loading drawer 280 is configured to support the carrier 300 (or 600) on a first shelf 286 and a second shelf 292. As shown in Figures 6 and 7, the carrier 300 is supported in the loading drawer 280 with the first end 304 of the carrier base 302 supported on the first shelf 286 and the second end 306 of the carrier base 302 supported on the second shelf 292. A sensor 297, which may include an optical sensor in the housing 102 (see Figure 5), can be provided to detect the presence of the carrier 300 (or 600) in the loading drawer 280.

[0143] When the carrier 300 is supported within the loading drawer 280, the first locator pin 288 of the loading drawer 280 is received in the shell locator hole 340, and the second locator pin 294 of the loading drawer 280 is received in the shell locator slot 342. The locator pins 288 and 294, as well as the shell locator hole 340 and shell locator slot 342 formed on the carrier base 302, facilitate the precise positioning of the carrier 300 within the loading drawer 280 and prevent lateral sliding of the carrier 300 relative to the loading drawer 280. To accommodate machining tolerances and manufacturing tolerances, the carrier 300 is positioned within the loading drawer 280 by a shell locator hole 340 at one end of the carrier 300 and a shell locator slot 342 at the other end of the carrier 300, the shell locator slot 342 being elongated to accommodate variations in the spacing between the first locator pin 288 and the second locator pin 294.

[0144] In alternative embodiments, locator pins may be provided on the carrier and locator holes may be provided on the loading drawer. For example, the carrier 300 may include locator pins projecting downward at the locations of a shell locator hole 340 and a shell locator slot 342, which engage with locator holes (e.g., one locator hole and one locator slot) formed in the loading drawer 280 at the locations of a first locator pin 288 and a second locator pin 294. In another embodiment, the carrier includes more or fewer locator holes / slots or locator pins that align with a corresponding number of locator pins or locator holes / slots on the loading drawer, respectively.

[0145] In various embodiments, it is preferable that when the loading drawer 288 is pulled out to the open position (i.e., extending from the housing 102), the carrier 300 is not removed from or removable from the loading drawer 280, so that the MRU 160 (or other consumables configured to be held by different carriers) can be loaded into the carrier 300. Conversely, when the loading drawer 288 is in the closed position (i.e., inserted into the module housing 102), the carrier 300 needs to be removable from the loading drawer 280 so that the carrier 300 can be removed from the loading drawer 280 by the conveyor 120 and moved to one of the holding shelves 104 or to the input module 230. Therefore, the loading drawer 280 includes a locking mechanism that locks the transport body 300 to the loading drawer 280 when the drawer 280 is in the open position, and releases the transport body 300 from the loading drawer 280 when the drawer 280 is in the closed position.

[0146] In this embodiment, the locking mechanism is provided by a pivot latch 290 and a sliding latch 296. The pivot latch 290 is configured to pivot with respect to the first shelf 286 between a locked position located on a portion of the first end 304 of the carrier base 302 and a released position that does not extend over any portion of the carrier base 302. The sliding latch 296 is configured to slide in and out of the receiver 295 between an extended or locked position located on a portion of the second end 306 of the carrier base 302 and a retracted or released position that does not extend over any portion of the carrier base 302.

[0147] The pivot latch 290 is spring-biased to the locked position, for example by a torsion spring, and the sliding latch 296 is biased to the extended position, for example by a linear spring. Thus, without any external mechanism or force to overcome the biasing of the pivot latch 290 and the sliding latch 296, the carrier 300 is locked to the loading drawer 280 by the latches 290 and 296. This is the state when the loading drawer 280 is in the open or pulled-out position. As shown in Figure 6, when the loading drawer 280 is in the closed position, the lower end of the pivot latch 290 contacts a hard stop in the module 100, rotating the pivot latch 290 from the locked position to the released position (counterclockwise in the illustrated embodiment), thereby releasing the first end 304 of the carrier base 302. Similarly, when the loading drawer 280 is in the closed position, the sliding latch 296 contacts a hard stop that pushes the sliding latch 296 into the retracted position within the receiver 295, thereby releasing the second end 306 of the carrier base 302. Thus, once the loading drawer 280 is fully inserted into the module housing 102, the carrier 300 is released from the loading drawer 280 and can be moved by the conveyor 120 to another position within the module 100 or the input module 230.

[0148] The receiving baler 350 is configured to pack the MRU 160, held on a carrier 300 (or 600) supported within an input loading shelf 280, toward a second end of the carrier 300 where hard stops 316, 318 are located, thereby packing the MRU 160 into a relatively dense pack of MRU (i.e., the MRU 160 are pushed together so that adjacent MRU 160 are in contact with each other). The receiving baler 350 includes a baler carriage 362 coupled to a baler track 356 (e.g., a linear bearing mounted on the upper panel 103 of the housing 102), and a baler 360 (see also Figure 7A) configured to translate bidirectionally (e.g., slide or roll) along the track 356. The baler carriage 362 is attached to a baler drive belt 368 coupled to a baler motor 352, which may be a stepper motor, for powered translation of the baler 360 along the baler track 356.

[0149] In other embodiments, the packaging machine 360 ​​may be moved automatically in a linear fashion by other means such as a rack and pinion, a drive screw, or a hydraulic or pneumatic piston.

[0150] As shown in Figure 7A, in various embodiments, the packaging machine 360 ​​further comprises a horizontal section 364 connected to a packaging machine carriage 362 and a contact section 366 extending downward from the horizontal section 364. In the embodiment shown in Figure 7, the contact section 366 is aligned with the gap between the support rails 312, 314 of the transport body 300 located within the loading shelf 280. As the packaging machine 360 ​​moves along the packaging machine track 356, the contact section 366 moves between the support rails 312, 314 and contacts the central receiver 162 of the MRU 160 located between the support rails 312, 314, packaging the MRU against the hard stops 316, 318. The contact section 366 may also be aligned to pass between a pair of stops 283. The horizontal section 364 of the packaging machine 360 ​​contacts the outermost MRU 160 above the support rails 312, 314, and keeps the MRU 160 perpendicular to the support rails 312, 314 while it is being pressed in (i.e., keeps the MRU 160 generally perpendicular to the longitudinal direction of the support rails 312, 314) in order to prevent the MRU 160 from bending and becoming immobile on the support rails 312, 314.

[0151] A position encoder, such as a rotary encoder 354 operably coupled to the packaging motor 352, detects the longitudinal position of the packaging machine 360 ​​relative to a home position detected by a home sensor 355, the home sensor 355 may comprise an optical sensor as described below. For example, the longitudinal position of the packaging machine 360 ​​may be determined by the number of encoder counts performed by the motorized movement of the packaging machine 360 ​​from the detected home position. In an embodiment, the home position may be the position where the packaging machine 360 ​​is fully retracted, for example, as shown in Figure 7. Alternatively, if the packaging motor 352 is a stepper motor, the longitudinal position of the packaging machine 360 ​​may be determined by counting motor steps. The packaging mechanism 350 may be calibrated to determine the number of MRUs 160 held on the carrier 300 based on the longitudinal position of the packaging machine 360 ​​and the width of the MRUs 160 in which the MRUs are packaged together. The position in which the MRUs are packaged together may be determined, for example, by a threshold resistance detected by the packaging motor 352.

[0152] Input module In the illustrated embodiment, the input module 230 includes a receiver dispensing station configured to receive a carrier holding one or more receivers and to provide receivers for input to the equipment.

[0153] Details of the input module 230 are shown in Figures 22 to 25. The input module 230 is configured to hold a carrier (e.g., carrier 300 or carrier 600) loaded with one or more consumables (e.g., MRU 160) inside or adjacent to a processing device (e.g., processing device 400) and to provide the consumables for collection into the device by a distribution mechanism (e.g., distributor 430) within the device.

[0154] Figures 22 and 23 are front, right rear, and right perspective views, respectively, of the input module 230 without the carrier 300 or 600 contained therein. Figure 24 is a right side perspective view of the input module 230 with a carrier holding multiple MRUs 160. Figure 25 is a front left perspective view of the input module 230 with a receiver distribution head 432 of the receiver distributor 430 of the processing equipment 400 that extracts the MRUs 160 from the input module 230.

[0155] As described above, the input module 230 may be a component of the equipment in which the conveyor / storage module 100 is coupled with the conveyor 120, which is positioned between the input module 230 on one side of the conveyor 120 and the holding shelf 104 and loading drawer 280 on the opposite side of the conveyor 120. See also Figure 1.

[0156] Referring to Figures 22 and 23, the input module 230 includes a first carrier shelf 232 for supporting the first end 304 of the carrier base 302 of the carrier 300 (or the first end 604 of the carrier 600). A carrier locator pin 234 protrudes above the first carrier shelf 230 and is received in a shelf locator hole 340 formed in the bottom of the carrier base 302 of the carrier 300. Referring to Figure 23, the input module 230 further includes a second carrier shelf 236 for supporting the second end 306 of the carrier base 302 of the carrier 300. A carrier locator pin 238 protrudes above the second carrier shelf 236 and is received in a shelf locator slot 342 formed in the bottom of the carrier base 302 of the carrier 300. The first transport shelf 232 and the second transport shelf 236 are spaced apart to define an open gap 235 between them.

[0157] In alternative embodiments, locator pins may be provided on the carrier, and locator holes may be provided on the first carrier shelf and the second carrier shelf. For example, carrier 300 may include locator pins projecting downward at the locations of a shelf locator hole 340 and a shelf locator slot 342, which engage with locator holes (e.g., one locator hole and one locator slot) formed in the first carrier shelf 232 and the second carrier shelf 236 at the locations of carrier locator pins 234, 238. In another embodiment, carrier includes more or fewer locator holes / slots or locator pins that align with a corresponding number of locator pins or locator holes / slots on the first carrier shelf and the second carrier shelf.

[0158] The input module 230 may include sensors, such as the carrier detection sensor 264 shown in Figure 23, for detecting that the carrier 300 is arranged within the input module 230. Details of an exemplary optical sensor are described below.

[0159] In some examples, the input module 230 includes a housing 270 having an input module positioning tab 256 extending from there.

[0160] The extruder 240 is configured to pack the MRU 160, held in a carrier 300 (or 600; all references to carrier 300 are also applicable to carrier 600 unless otherwise noted, whether explicitly stated or not) located within the input module 230, toward the first end of carrier 300 where the retaining tabs 320, 322 (or 620, 622) are located, to pack the MRU 160 into a relatively dense pack of MRU. (i.e., the MRU 160 are pushed together so that adjacent MRU 160 are in contact with each other). In this respect, the extruder 240 functions as a packing mechanism. The extruder 240 includes an extruder carriage 248 coupled to an extruder track 250, and is configured to translate bidirectionally (e.g., sliding or rolling) along the track 250. The extruder carriage 248 is mounted on an extruder drive belt 254 coupled to an extruder motor 252, which may be a stepper motor and / or may be operably coupled to a rotary encoder 253, for powered translation of the extruder carriage 248 along the extruder track 250. In various embodiments, the extruder 240 further comprises an extruder arm extending from the extruder carriage 248, which may include a support portion 242 extending upward from the extruder carriage 248, a lateral portion 244 extending laterally from the support portion 242, and a contact portion 246 extending downward from the lateral portion 244. In the embodiment shown in Figure 25, the contact portion 246 is aligned with the gap between the support rails 612 and 614 of the transport body 600 located within the input module 230, so that as the extruder 240 moves along the extruder track 250, the contact portion 246 moves between the support rails 612 and 614 and makes contact with the central receiver 162 of the MRU 160 located between the support rails 612 and 614.

[0161] To arrange the carrier 300, on which one or more MRUs 160s are supported, within the input module 230, the extruder 240 is moved to a standby position (the leftmost end of the housing 270 in the embodiments shown in Figures 22 to 24) to allow the carrier 300 to be arranged within the input module 230. An extruder home sensor may be provided to detect that the extruder 240 is in the standby position and to provide a confirmation signal. In one embodiment, the home sensor comprises a slotted optical sensor 249 (see Figure 25) that detects a tab 243 extending from the extruder 240 when the extruder 240 is in the standby position. Other types of sensors, including contact sensors and proximity sensors, may be used for the home sensor. After the carrier 300 is arranged in the input module 230, as shown in Figure 24, the extruder 240 is operated to translate laterally relative to the MRUs 160s supported on the carrier 300. The force applied by the extruder 240 to the MRU 160 causes the MRU to slide along the support rails 312, 314 toward the retaining tabs 320, 322, pushing the rightmost MRU 160 into the recovery dock 260 after bending the retaining tabs 320, 322 on the support rails 312, 314, where the MRU can be recovered by a distributor within the machine. A contact sensor 258 (see Figure 22) detects when one of the MRU 160 has been pushed into the recovery dock 260, thereby causing the extruder 240 to stop translating and thus stop applying force to the MRU. A push-down mechanism 262 may comprise a flexible metal tab, one end of which is attached to the housing 270 and extending laterally from there above the recovery dock 260, which contacts the top of the MRU 160 when the MRU is pushed into the recovery dock 260. Upon contact with the MRU160, the push-down mechanism 262 bends upward, and the elasticity of the mechanism generates a force that pushes the MRU160 down into the loading dock 260.

[0162] The support guide plate 268 (see Figure 22) is positioned adjacent to the recovery dock 260, spaced apart from the guide panel 274, and generally parallel to it.

[0163] As shown in Figure 25, once the MRU 160 is pushed out of the transport body 600 and onto the retrieval dock 260, the MRU 160 can be pulled out of the retrieval dock 260 by the receiver distribution head 432 of the receiver distributor 430 and pulled into processing equipment (e.g., processing equipment 400). In detail, in the illustrated embodiment, the receiver distributor head 432 is moved on the transport track 434 to a position adjacent to the retrieval dock 260 and rotated to a position operably aligned with the MRU 160. This translation of the receiver distributor head 432 to the “pickup” position can be actuated by the MRU 160 making contact with the contact sensor 258. Once the receiver distributor head 432 is in the pickup position, the distribution head hook 436 extends from the distribution head housing 438 and engages with the MRU operating structure 166 of the MRU 160 positioned on the retrieval dock 260. Next, the distribution head hook 436 retracts into the distribution head housing 438, pulling the MRU 160 out of the recovery dock 260 and into the housing 430. Once the MRU 160 is pulled out of the recovery dock 260, it passes between the guide plate 268 and the guide panel 274 (see Figure 22), aligning itself with the opening (not shown) and aligning itself with the distribution head housing 438. The leading edge 272 of the guide plate 268 can be spread outward to change the orientation of the MRU 160, which is not aligned with the space between the guide plate 268 and the guide panel 274. In addition, by packaging the MRU in the extruder 240, the MRU is less likely to tilt or twist on the carrier 300, thereby being properly positioned for placement on and recovery from the recovery dock 260.

[0164] As shown in Figure 25, MRU 160 is no longer on the carrier 600, and the extruder 240 has returned to its standby position. If one or more MRUs remained on the carrier 600, the extruder 240 would have been sawn to a position in contact with (or closely adjacent to) the last remaining MRU on the carrier 600. Once the contact sensor 258 indicates that MRU 160 is no longer in contact with an MRU after it has been withdrawn from the recovery dock 260, the extruder 240 is activated to push another MRU out of the carrier 600 and into the recovery dock 260.

[0165] A position encoder, such as a rotary encoder 253 operably coupled to the extruder motor 252, detects the longitudinal position of the extruder 240 based on the rotational output of the extruder motor 252 when the MRU is in contact with the sensor 258 (alternatively, if the extruder motor 252 is a stepper motor, the longitudinal position of the extruder 240 can be determined by counting motor steps), and the input module 230 can be calibrated to determine the number of MRUs 160 currently held on the carrier 300 based on the longitudinal position of the extruder 240 and the width of the MRUs 160. After the equipment has recovered the MRUs 160 from the recovery dock 260, the sensor 258 detects the absence of the MRUs 160 and thereby activates the extruder 240 to push the next MRU from the carrier 300 into the recovery dock 260. In an alternative embodiment, the next MRU may be pushed out of the carrier and not pushed onto the recovery dock 260 until the equipment signals that the next MRU is needed.

[0166] Conveyor / Lifting equipment The features of the conveyor 120 are shown in Figures 15 to 20. In this embodiment, the conveyor 120 includes a conveyor chassis 122 comprising a horizontally oriented base frame 124, a first support column 126 attached to the first end of the base frame 124, and a second support column 128 attached to the second end of the base frame 124. Note that the first support column 126 and the second support column 128 are not shown in Figure 17, which is an exploded view of the conveyor 120. The lift stand 180 (also called the transporter support stand or support stand) is transported by a lateral actuator and coupled to the support chassis 122 by a lateral actuator. In one embodiment, the lateral actuator includes a scissors actuator 140 configured to move the lift frame 180 laterally relative to the support chassis 122 in a first direction, direction "D", to one side of the support chassis 122, or, as shown in Figure 18, in a second direction, direction "E", to the opposing sides of the support chassis 122. Therefore, the lateral actuator is configured to laterally translate the lift frame 180 from a position aligned with the support chassis 122 (as shown in Figure 15) to a first laterally displaced position shown in Figure 16, which is laterally aligned with one of the holding shelves 104 (holding shelves 104 are not shown in Figure 16), or to a second laterally displaced position shown in Figure 18, which is laterally aligned with the first and second transport shelves 232 and 236 of the input module 230 (the first and second transport shelves 232 and 236 are not shown in Figure 18).

[0167] In this embodiment, the vertical guide rod extends through a bore 127 formed through a first support column 126 of the support chassis 122, and the vertical guide rod extends through a bore 129 formed through a second support column 128 of the support chassis 122. Figure 2 (and Figure 21) shows a first guide rod 156 extending through the first support column 126. A similar guide rod 158 (see Figure 21) extends through the second support column 128.

[0168] As shown in Figure 21, the conveyor 120 is coupled to a conveyor lift 210 configured to move the conveyor 120 vertically, upward or downward in direction "B", within the housing 102 of the conveyor / storage module 100. Referring to Figure 21, the conveyor lift 210 includes a first drive pulley 216 and a second drive pulley 217 connected to each other by a connecting shaft 218. A lifter drive motor 212, which may be a stepper motor and / or operably coupled to a rotary encoder 213, is coupled to the drive pulleys 216, 217 and the connecting shaft 218 by a drive belt 214. A first lifter belt 220 is wrapped around the first drive pulley 216 and a first idler pulley 224. Similarly, a second lifter belt 222 is wrapped around the second drive pulley 217 and a second idler pulley 225. The first elevator belt 220 is connected to the first support column 126 of the support chassis 122 by, for example, clamps 134 and 135. Similarly, the second elevator belt 222 is connected to the second support column 128 of the support chassis 122 by, for example, clamps 136 and 137. In various embodiments, a counterweight 228 can be attached to the first elevator belt 220 and the second elevator belt 222.

[0169] From Figure 21, it can be seen that the rotation of the connecting shaft 218 and drive pulleys 216, 217 in direction "C" by the elevator drive motor 212 and drive belt 214 results in vertical translation of the conveyor 120 upward or downward, according to the direction of rotation of the pulleys 216, 217.

[0170] In other embodiments, power means other than drive belts and drive pulleys are intended to provide vertical translation of the conveyor 120. For example, the conveyor 120 may be moved upward or downward by a lead screw mechanism including one or more vertically oriented power-driven lead screws that are mounted to the support chassis 122 of the conveyor 120 or operably coupled to a coupled screw follower.

[0171] In various embodiments, the locator flag 130 extends laterally from one of the support columns, such as the support column 126. The locator flag 130 is used by one or more sensors (not shown) located within the housing 102 along the vertical path of the conveyor 120 to detect the vertical position of the conveyor 120, for example, by detecting the locator flag 130 passing between the light-emitting element and receiver of a photodetector. Thus, the flag 130 and associated optical sensors can be used as home sensors to detect a specified position of the conveyor based on the position of the sensors. In other embodiments, two or more sensors can be used to detect multiple conveyor positions, each corresponding to a different sensor position.

[0172] Referring to Figures 15 to 18, the lift base 180 includes a first carrier locator pin 190 and a second carrier locator pin 191, respectively, and is configured to support a carrier 300 (or 600) as shown in Figure 20. When the carrier 300 is supported on the lift base 180, the first carrier locator pin 190 is received in the lift base locator hole 344, and the second carrier locator pin 191 is received in the lift base locator slot 346. The locator pins 190 and 191, as well as the lift base locator hole 344 and lift base locator slot 346 formed in the carrier base 302, facilitate the precise positioning of the carrier 300 on the lift base 180 and prevent lateral sliding of the carrier 300 on the lift base 180.

[0173] In alternative embodiments, locator pins may be provided on the carrier and locator holes may be provided on the lift base. For example, the carrier 300 may include locator pins projecting downward at the locations of a lift base locator hole 344 and a lift base locator slot 346, which engage with locator holes (e.g., one locator hole and one locator slot) formed in the lift base 180 at the locations of a first locator pin 190 and a second locator pin 191. In another embodiment, the carrier includes more or fewer locator holes / slots or locator pins that align with a corresponding number of locator pins or locator holes / slots on the lift base, respectively.

[0174] A carrier detection sensor 204 (see Figure 19) can be provided to detect a carrier 300 supported on the lift frame 180 when the lift frame moves to a retracted position. Details of an exemplary carrier detection sensor, which may be an optical sensor, are shown in Figure 26. In an embodiment, the carrier detection sensor 204 is mounted on a second support column 128 of the support chassis 122 and comprises an L-shaped bracket having a support portion 206 and a lateral portion 208. A light emitter is located at one distal end of the support column and the lateral portions 206 and 208, and a light receiver is located at the other distal end of the support column and the lateral portions 206 and 208. A light beam represented by line 209 is directed between the light emitter and the receiver at the distal ends of the support column and the lateral portions 206 and 208. The ends of the carrier 300 (or 600) supported on the lift frame 180 extend beyond the ends of the lift frame 180. Therefore, when the lift platform 180 is moved to the retracted position shown in Figure 15, one of the excess-extending ends of the transport body 300 passes through the lateral portion 208 of the L-shaped bracket, blocking the beam 209 between the sensor's light emitter and receiver, thereby generating a signal indicating the presence of the transport body on the lift platform.

[0175] Other optical detection sensors described herein, such as the carrier detection sensor 115 of the holding shelf 104 shown in Figure 6, the packaging machine home sensor 355 shown in Figure 7, the carrier detection sensor 297 of the loading drawer 280 shown in Figure 5, the drawer closing sensor 299 shown in Figures 5 and 7, and the carrier detection sensor 264 of the input module 230 shown in Figure 23, may have the same configuration and function as the carrier detection sensor 204 shown in Figure 26.

[0176] Scissors Actuator Details of the scissors actuator 140 are shown in Figures 16 to 20.

[0177] The scissors actuator 140 comprises a power arm 142 having a first portion 142a and a second portion 142b. The power arm 142 is pivotably mounted to the support chassis 122 (base frame 124) by a pivot shaft 152 and mounted to the lift frame 180, and is translationally mounted to the support chassis 122 in a sliding body 184 located within a frame sliding body track 182. The second portion 142a of the power arm 142 extends into a bearing 186 located within the sliding body 184 and can be mounted to the sliding body 184 by a pivot shaft 143 protruding from one or both sides of the sliding body 184, so that the bearing 186 rolls against the sides of the sliding body track 182 as the sliding body 184 translates along the track 182.

[0178] The scissors actuator 140 comprises a first portion 144a and a second portion 144b, and further comprises a driven arm 144 attached to the base frame 124 in a post 155 that protrudes from the driven arm sliding body 154, which is positioned in the base frame raceway 132 and attached to the lift frame 180 by a post 149 and pivot connection 188. The post 155 is positioned within the sliding body 154 and may extend into a bearing protruding from one or both sides of the sliding body 154, so that the bearing rolls against the sides of the sliding body raceway 132 as the sliding body 154 translates along the raceway 132.

[0179] The first portion 142a and the second portion 142b of the power arm 142 are fixedly coupled to each other at the coupling 146, and the first portion 144a and the second portion 144b of the driven arm 144 are fixedly coupled to each other at the coupling 146, and the power arm 142 and the driven arm 144 are rotatably coupled to each other at the coupling 146. As shown in Figure 17, in one embodiment, the coupling 146 includes a swivel ring (sometimes called a swivel bearing) having an inner ring 146a and an outer ring 146b rotatable relative to the inner ring 146a. An exemplary swivel ring is the iglide® PRT swivel ring, available from igus®. The first portion 142a of the power arm 142 is attached to the second portion 142b by fasteners 141a, 141b (e.g., pins, screws, or bolts) extending through the inner ring 146a of the coupling 146. The first portion 144a of the driven arm 144 is attached to the second portion 144b by a fastener 147 (e.g., a pin, screw, or bolt) that extends through the ring 145b of the second portion 144b, the outer ring 146b of the joint 146, and the ring 145a of the first portion 144a.

[0180] Referring to Figure 19, a scissors drive motor 192, such as a stepper motor, mounted on the base frame 124 includes a drive pulley 194 coupled to a drive pulley 198 which is coupled to a pivot shaft 152 via a drive belt 196. An encoder 202 may be coupled to the pivot shaft 152 to monitor the rotational position of the shaft.

[0181] Referring to Figure 16, the clockwise rotation of the power arm 142, powered by the scissors drive motor 192, drive belt 196, and pivot shaft 152, causes lateral translation of the lift frame 180 in the first direction "D". Conversely, as shown in Figure 18, the counterclockwise rotation of the power arm 142, powered by the scissors drive motor 192, drive belt 196, and pivot shaft 152, causes lateral translation of the lift frame 180 in the opposite direction "E".

[0182] The sensor 148 may be a slot optical sensor, positioned adjacent to the first portion 142a of the power arm 142, and detects a sensor flag 150 having a lateral flange extending from the end of the power arm 142 adjacent to the pivot shaft 152. In one embodiment, the sensor 148 detects the edge of the sensor flag 150 to determine the “home” position of the power arm 142 (and thus the home position of the scissors actuator 140). Other positions of the power arm 142 relative to the home position are determined by the encoder 202.

[0183] The conveyor 120 is configured to transport the carrier 300 between different holding shelves 104, between the loading drawer 280 and one of the holding shelves 104, between one of the holding shelves 104 and the input module 230, or between the loading drawer 280 and the input module 230 (unless otherwise stated, whether explicitly stated or not, all references to the carrier 300 are also applicable to the carrier 600). The conveyor 120 performs this transport operation by lifting the carrier 300 from the holding shelf 104 using the loading drawer 280 or the lift stand 180, moving the conveyor 120 to a different holding shelf 104, loading drawer 280, or input module 230 using the transport elevator 210, and then arranging the carrier in the new location using the lift stand.

[0184] More specifically, to transport the transporter 300 from a first holding shelf of the holding shelves 104 to a second holding shelf of the holding shelves 104, the transporter lift 210 positions the transporter 120 and lift base 180 adjacent to the first holding shelf 104 where the transporter 300 to be moved is positioned. Sensors may be used to indicate the position of the transporter 120 relative to the desired holding shelf 104. In an embodiment, a sensor adjacent to the desired holding shelf 104 detects a locator flag 130. Alternatively, or additionally, an encoder coupled to the lifter drive motor 212, such as a rotary encoder 213, is used to control the vertical positioning of the transporter 120 relative to the home position detected by a sensor (not shown) that detects the locator flag 130.

[0185] As shown in Figure 15, the lift stand 180 is initially in a retracted position relative to the support chassis 122. Once the lift stand 180 is positioned adjacent to the first holding shelf 104, the lift stand 180 is extended by the scissors actuator 140 in a first direction relative to the support chassis 122 to a position below the transport body 300, as shown in Figure 16. In this embodiment, an encoder 202 coupled to a pivot shaft 152 that detects the rotation of the power arm 142 of the scissors actuator 140 is used to control the amount of lateral translation of the lift stand 180.

[0186] As schematically shown in Figure 4A, the length of the lift stand 180 is shorter than the length of the open area 116 between the first shelf portion 112 and the second shelf portion 114 of the holding shelf 104. As shown in Figure 11, the lift stand locator hole 344 and the lift stand locator slot 346 formed at the bottom of the transport base 302 are located inside the shelf locator hole 340 and the shelf locator slot 342 formed at the bottom of the transport base. Furthermore, as shown in Figure 4A, the first transport locator pin 190 and the second transport locator pin 191 of the lift stand 180 are similarly located inside the first locator pin 110 and the second locator pin 111 of the holding shelf 104.

[0187] Once the lift stand 180 is positioned below the transport body 300 held on the holding shelf 104 (i.e., the lift stand is laterally aligned with the transport body 300 and the holding shelf 104), the conveyor 120 is raised by the conveyor lift 210 until the lift stand 180 enters the open area 116 and contacts the bottom of the transport body 300. The conveyor lift 210 continues to raise the conveyor 120 and the lift stand 180, and the first transport body locator pin 190 and the second transport body locator pin 191 enter the lift stand locator hole 344 and the lift stand locator slot 346 formed in the bottom of the transport body base 302, respectively. The transport lifter 210 continues to raise the transporter 120 until the lift base 180 lifts the transporter 300 from the holding shelf 104 and the first locator pin 110 and the second locator pin 111 are completely away from the shelf locator hole 340 and the shelf locator slot 342 of the transporter 300. In one embodiment, the vertical position at which the lift base 180 contacts the transporter 300 within a particular holding shelf 104 is known, for example, by a system self-repair process described below, and thus the additional height of the lift base 180 required to lift the transporter 300 from the first locator pin 110 and the second locator pin 111 can be determined from the heights of the first locator pin 110 and the second locator pin 111.

[0188] As shown in Figure 20, with the transporter 300 supported on the lift stand 180, the lift stand is retracted by the scissors actuator 140 to the retracted position shown in Figure 15 (the transporter 300 is not shown in Figure 15). A transporter detection sensor 204 (see Figure 19) can be provided to detect the transporter 300 supported on the lift stand 180 when the lift stand moves to the retracted position. The conveyor 120 is then raised or lowered by the conveyor lift 210 to another holding shelf 104. To arrange the transporter within the holding shelf 104, the lift stand 180 is extended by the scissors actuator 140 to a position above the holding shelf 104 (i.e., the lift stand 180 is laterally aligned with the holding shelf 104). In this embodiment as well, an encoder 202 coupled to the pivot shaft 152 is used to control the amount of lateral translation of the lift stand 180. Next, the transport lift 210 lowers the transporter 120 until the transport body 300 is supported on the first shelf portion 112 and the second shelf portion 114 of the holding shelf 104. As the lift base 180 is lowered, the first locator pin 110 and the second locator pin 111 of the first shelf portion 112 and the second shelf portion 114 enter the shelf locator hole 340 and the shelf locator slot 342 formed in the bottom of the transport body base 302, respectively. Once the lift platform has been lowered sufficiently and the carrier pins 190 and 191 of the lift platform 180 have moved away from the lift platform locator holes 344 and lift platform locator slots 346 formed in the bottom of the carrier base 302, the lift platform 180 is retracted by the scissors actuator 140 to the retracted position shown in Figure 15, and the carrier 300 remains supported on the new holding shelf 104.

[0189] To transport the transporter 300 from the loading drawer 280 to one of the holding shelves 104, the transporter lift 210 positions the transporter 120 and lift base 180 adjacent to the loading drawer 280. In the embodiment, a sensor adjacent to the desired holding shelf 104 detects a locator flag 130. Alternatively, or additionally, an encoder coupled to the lifter drive motor 212 is used to control the vertical positioning of the transporter 120 relative to the home position detected by a sensor (not shown) that detects the locator flag 130.

[0190] Next, the lift stand 180 is laterally extended by the scissors actuator 140 to a position below the transport body 300 held in the loading drawer 280. In this embodiment, an encoder 202 coupled to the pivot shaft 152 is used to control the amount of lateral translation of the lift stand 180. The conveyor 120 is then raised by the conveyor lift 210 until the lift stand 180 enters the open area 298 between the first shelf 286 and the second shelf 292 and contacts the bottom of the transport body 300. The conveyor lift 210 continues to raise the conveyor 120 and the lift stand 180, and the first transport body locator pin 190 and the second transport body locator pin 191 enter the lift stand locator hole 344 and the lift stand locator slot 346 formed in the bottom of the transport body base 302, respectively. The transport lifter 210 raises the transporter 120 until the lift base 180 lifts the transporter 300 away from the loading drawer 280 and the first and second locator pins 288 and 294 are completely away from the shelf locator holes 340 and shelf locator slots 342 of the transporter 300. In one embodiment, the vertical position in which the lift base 180 contacts the transporter 300 in the loading drawer 280 is known, for example, by a system self-repair process described below, and thus the additional height of the lift base 180 required to lift the transporter 300 away from the first and second locator pins 288 and 294 can be determined from the heights of the first and second locator pins 288 and 294.

[0191] As shown in Figure 20, with the transporter 300 supported on the lift base 180, the lift base is retracted by the scissors actuator 140 to the retracted position shown in Figure 15, and then transported to one of the holding shelves 104 as described above, or to the input module 230 as described below.

[0192] Similarly, to transport the transporter 300 to the holding drawer 280, the transporter lift 210 positions the transporter 120 and lift base 180 adjacent to the loading drawer 280, on which the transporter 300 is supported. The lift base 180 is then extended by the scissors actuator 140 to a position above the loading drawer 280, and the transporter 120 is then lowered by the transporter lift 210 until the lift base 180 enters the open area 298 between the first shelf 286 and the second shelf 292. The transporter lift 210 continues to lower the transporter 120 until the transporter 300 is supported by the first shelf 286 and the second shelf 292, and the first locator pin 288 and the second locator pin 294 of the loading drawer enter the shelf locator hole 340 and shelf positioning slot 342 of the transporter 300. The transport lift 210 continues to lower the transport 120 and the lift stand 180 until the first transport locator pin 190 and the second transport locator pin 191 are separated from the lift stand locator hole 344 and the lift stand locator slot 346 formed at the bottom of the transport base 302, respectively. With the transport 300 supported on the loading shelf 280, the lift stand 180 is retracted by the scissors actuator 140 to the retracted position shown in Figure 15.

[0193] To transport the transporter from the loading drawer 280 or holding shelf 104 to the input module 230, the transporter 300 is first removed from the loading drawer 280 or holding shelf 104, possibly using the transporter 120 described above. With the transporter 300 supported on the lift base 180, as shown in Figure 20, the lift base is retracted to the retracted position shown in Figure 15 by the scissors actuator 140. The transporter 120 is then raised or lowered to the input module 230 by the transporter lift 210, as necessary. To position the transporter 300 within the input module 230, the lift base 180 is extended by a scissors actuator 140 to a position above the first transporter shackle 232 and the second transporter shelf 236 within the input module 230, and the lift base 180 is positioned within the gap 235 between the first transporter shackle 232 and the second transporter shelf 236. The transporter lift 210 then lowers the transporter 120 until the transporter 300 is supported on the first transporter shackle 232 and the second transporter shelf 236 of the input module 230. As the lift stand 180 is lowered, the first and second carrier locator pins 234 and 238 of the first carrier shelf 232 and the second carrier shelf 236 enter the shelf locator hole 340 of the carrier base 302 and the shelf locator slot 342 formed in the bottom of the carrier, respectively. Once the lift stand has been lowered sufficiently and the carrier pins 190 and 191 of the lift stand 180 have moved away from the lift stand locator hole 344 and the lift stand locator slot 346 formed in the bottom of the carrier base 302, the lift stand 180 is retracted by the scissors actuator 140 to the retracted position shown in Figure 15, and the carrier 300 remains supported within the input module 230.

[0194] To remove the transporter 300 from the input module 230, the lift stand 180 is positioned in the gap 235 between the first transporter shelf and the second transporter shelves 232, 236 beneath the transporter 300. The lift stand is then raised by the transporter lift 210 until the lift stand 180 contacts the bottom of the transporter 300. The transporter lift 210 continues to raise the transporter 120 and the lift stand 180, and the first transporter locator pin 190 and the second transporter locator pin 191 enter the lift stand locator hole 344 and the lift stand locator slot 346 formed in the bottom of the transporter base 302, respectively. The transport lifter 210 raises the transport body 300 from the first transport body shelf 232 and the second transport body shelf 236, and continues to raise the transporter 120 until the first transport body locator pin 234 and the second transport body locator pin 238 are completely away from the shelf locator slot 342 and shelf locator hole 340 of the transport body 300. The scissors actuator 140 then moves the lifter 180 and the transport body 300 back to the retracted position shown in Figure 15.

[0195] control system Figure 28 is a schematic block diagram showing the control architecture of the conveyor storage module 100. An exemplary control architecture may include a control unit 550 that monitors, communicates with, and controls an aspect of the conveyor storage module 100, which includes a holding shelf 104, a loading drawer 280, an input module 230, a conveyor lifter 210, and a scissors actuator 140. The extruder motor 252 of the input module 230, the lifter drive motor 212 of the conveyor lifter 210, and the scissors drive motor 192 of the scissors actuator 140 are coupled to and controlled by the control unit 550, which is also connected to a power supply 460 controllable by the control unit 550. The control unit 550 provides power and operation control signals to the motors 252, 212, and 192. The control unit 550 may also receive data from motors 252, 212, and 192, as well as other feedback sensor signals, in the form of rotational encoder counts from encoders 253, 213, and 202, respectively.

[0196] The control unit 550 may include a computer system for running software (which may include firmware) that brings about the operation, control, and monitoring of the transporter storage module 100. The control unit 550 may be implemented via one or more logic elements, such as a computer, an embedded control unit, a programmable gate array, an application-specific integrated circuit, a programmable logic device, etc., and may include or access a data storage memory 552 which may include random access memory (RAM), read-only memory (ROM), flash memory, and other types of memory currently known or to be developed. The control unit 550 may also include additional memory, such as hard disk drives and / or removable storage drives, which represent magnetic tape drives, optical disc drives, USB slots, memory card interfaces, internet memory, cloud-based memory, or any storage medium or format currently known or to be developed. The memory devices and storage units used herein may include any storage medium for persistent and / or volatile storage of electronic data currently known or to be developed. Such data may be stored in a storage medium within a database, which may include any currently known or future-developed data structures and formats, such as relational databases, object databases, flat files, lists, or some combination thereof.

[0197] In alternative embodiments, part or all of the memory may include other similar means for enabling computer programs or other instructions to be loaded into the computer system. Such means may include, for example, removable storage units and interfaces. Such embodiments may include memory sticks and memory stick interfaces, secure digital cards and interfaces, and other portable media and interfaces, which enable software and data to be transferred to the control unit 550.

[0198] The software includes instructions stored on a non-temporary computer-readable medium, which, when executed by the logic elements of the control unit 550, cause the control and computing hardware to perform one or more automatic or semi-automatic processes.

[0199] The computer system of the control unit 550 may also include a communication interface that enables information (e.g., power, control and feedback signals, software, data, etc.) to be transferred between the control unit 550 and external devices. Embodiments of the communication interface may include a modem, a network interface (such as an Ethernet® card), a communication port, a PCMCIA slot and card, a USB port, a Firewire port, Bluetooth®, or any currently known or future-developed interface. The information is transferred in the form of signals through the communication interface, and these signals may be electronic signals, electromagnetic signals, optical signals, or other signals receivable by the communication interface.

[0200] The computer system of the control unit 550 may also include one or more input devices such as a touchscreen, stylus, keyboard, mouse or other pointing device, microphone, and data scanner (e.g., barcode, RFID, etc.). Various output devices may also be included in the computer system, including indicator lights, displays, printers, tactile (e.g., vibration) indicators, and audio speakers.

[0201] In this specification, terms such as “computer program medium,” “computer-readable medium,” and “computer-usable medium” are generally used to refer to media such as removable storage units, hard disks mounted on hard disk drives, and other means for providing software and data to the control unit 550.

[0202] The computer program (also called computer control logic) is either part of the control unit 550 or stored in one or more parts of memory 552 accessed by the control unit 550. The computer program may also be received via a communication interface. When executed, such a computer program may include algorithms, such as the algorithm shown in Figure 27, that enable the computer system of the control unit 550 to control the operation of the transporter storage module 100 in accordance with the embodiments disclosed herein.

[0203] In embodiments in which aspects of the subject matter disclosed herein are implemented using software, the software may be stored in a computer program product and loaded into the computer system of the control unit 550 using a removable storage drive, hard drive, interface, and / or communication interface. When the control logic (software) is executed by the processor of the control unit 550, it causes the processor to perform functional aspects of the subject matter described herein via the systems, devices, apparatus, sensors, encoders, etc. The operating system may perform basic tasks such as recognizing input from input devices, sending outputs to output devices, managing files and system resources, and managing various processes that embody computer programs running on the computer system.

[0204] The control unit 550 may comprise a standalone system dedicated to the transporter storage module 100, or one or more components of the control unit 550 (e.g., a processor, memory, interface, input / output device, etc.) may be a shared part of a global control unit that controls not only the transporter storage module 100 but also one or more components of the equipment or laboratory in which the transporter storage module 100 is a component.

[0205] As schematically shown in Figure 28, for each holding shelf 104, the control unit 550 receives a signal from the transporter detection sensor 115 to indicate whether or not the transporters 300, 600 are being held in one of the shelves 104.

[0206] With respect to the loading drawer 280, the control unit 550 may receive a signal from the transport detection sensor 297 to indicate whether the transports 300, 600 are held inside the loading drawer 280. The control unit 550 may also receive a signal from the drawer position sensor 299 to indicate whether the loading drawer 280 is in the closed position. The control unit 550 may also receive a signal from the door position sensor 293 to indicate the position of the door 106, whether it is open or closed (or closed or unclosed).

[0207] The control unit 550 may also receive signals from the packaging motor 352 and / or encoder 354 to detect the position of the packaging machine 360. The control unit 550 may also transmit control (power) signals to the packaging motor 352 to cause selective operation of the packaging motor 352.

[0208] The control unit 550 can further receive signals from a packaging machine home sensor 355, for example, an optical sensor, to detect whether the packaging machine 360 ​​is in a home or standby position, and can generate control signals, such as signals that result in the operation and control of the packaging machine motor 352 based on the signals received from the packaging machine home sensor.

[0209] The control unit 550 receives a signal from the drawer position sensor 299 to detect that the drawer 280 is closed, and then transmits a control signal to the packaging machine motor 352 so that the packaging machine 360 ​​can translate and package the MRU 160 on the carrier 300 after the drawer 280 has been detected in the closed position. In another embodiment, the control unit 550 may receive signals from the packaging machine motor 352 and / or encoder 354, from which the control unit 550 can determine the position of the packaging machine 360 ​​relative to the home position and calculate the number of MRU 160 held on the carrier 300.

[0210] With respect to the input module 230, the control unit 550 receives a signal from the transporter detection sensor 264 to indicate whether or not the transporters 300 and 600 are being held in the input module 230.

[0211] The control unit 550 may also receive signals from the motor 252 and / or encoder 253 to detect the position of the extruder 240. The control unit 550 may also transmit control (power) signals to the extruder motor 252 to cause selective operation of the motor 252.

[0212] The control unit 550 may also receive signals from an extruder home sensor, such as an optical sensor 249, to detect whether the extruder 240 is in a home position or a standby position, and may generate control signals, such as signals that result in the operation and control of the motor 252, based on the signals received from the extruder home sensor.

[0213] The control unit 550 may further receive a signal from the contact sensor 258 to detect that one of the MRUs 160 has been pushed into the recovery dock 260, and then send a control signal to the extruder motor 252 to stop the extruder 240 from translating and thus stop applying force to the MRU. Alternatively, the control unit 550 may receive a signal from the contact sensor 258 to detect that one of the MRUs 160 has been removed from the recovery dock 260, and then send a control signal to the extruder motor 252 to translate the extruder 240 and push the next MRU from the carrier into the recovery dock 260. In another embodiment, if the signal from the contact sensor 258 indicates that one of the MRUs 160 has been pushed into the recovery dock 260, the control unit 550 may receive signals from the motor 252 and / or encoder 253, and the control unit may determine the position of the extruder 240 relative to the home position from the signals and calculate the number of MRUs 160 remaining on the carrier 300. If the calculation determines that no MRU remains on the transporter, the control unit 550 sends a signal to the extruder motor 252, which moves the extruder 240 to the standby position. The movement of the extruder 240 to the standby position is confirmed by a signal from the optical sensor 249 to the control unit 550.

[0214] With respect to the transport elevator 210, the control unit 550 may receive signals from the elevator drive motor 212 and / or encoder 213 to detect the vertical position of the transport elevator 120 relative to the home position detected by the elevator home sensor 215, which detects the locator flag 130. The control unit 550 may also transmit a control (power) signal to the elevator drive motor 212 to bring about selective operation of the motor 212.

[0215] With respect to the scissors actuator 140, the control unit 550 can receive a signal from the transporter detection sensor 204 to indicate whether or not the transporters 300, 600 are held on the lift frame 180 when the lift frame moves to the retracted position.

[0216] The control unit 550 may receive signals from the scissors drive motor 192 and / or encoder 202 to detect the position of the lift platform 180. The control unit 550 may also transmit control (power) signals to the scissors drive motor 192 to cause selective operation of the motor 192.

[0217] The control unit 550 can further receive signals from the sensor 148 to detect whether the scissors actuator 140 (and thus the lift base 180) is in the home position or the retracted position, and can generate control signals, such as signals that result in the operation and control of the scissors motor drive 192, based on the signals received from the base home sensor.

[0218] position self-study It should be apparent that the operation of the transport / storage module 100 requires the precise and repeatable positioning of the transporter 120 and lift stand 180 relative to the loading drawer 280, holding shelf 104, and input module 230 in order to transfer consumables and transporters between various positions within the transport / storage module 100. Although the positions of the loading drawer 280, holding shelf 104, and input module 230 are substantially the same for each transport / storage module 100, in some embodiments, manufacturing tolerances and / or installation variations may result in variations in the final positions of the loading drawer 280, holding shelf 104, and input module 230 after the transport / storage module 100 has been mounted on processing equipment such as processing equipment 400.

[0219] In this embodiment, module 100 has a self-repair function, which, after the transport / storage module 100 is attached to processing equipment such as processing equipment 400, automatically determines and stores the appropriate positions of the transporter 120 and lift stand 180 for each of the holding shelf 104, loading drawer 280, and input module 230.

[0220] Figure 27 is a flowchart showing how a computer control unit, such as a control unit 550 that communicates with various position sensors, encoders, and motors within module 100, performs this self-repair process (algorithm) 500.

[0221] In step 502, the conveyor 120 is moved by the conveyor lift 210 to a vertical position adjacent to the expected position of the loading drawer 280. The vertical position of the conveyor can be determined and controlled by the control unit 550 by signals received from a rotary encoder 213 for detecting the vertical position of the conveyor 120 relative to the home position, which is detected by a signal transmitted to the lift drive motor 212 and a sensor 215 (see Figure 28) that detects a locator flag 130.

[0222] In step 504, the loading drawer positioning tab 276 is brought into contact with the lift base 180. The processor 550 controls the contact between the lift base 180 and the positioning tab 276 in one of several ways.

[0223] In one embodiment, the conveyor 120 is positioned by the conveyor lift 210 at a height known to be above the approximate expected position of the loading drawer 280 (or above the approximate position of the loading drawer positioning tab 276), and the scissors actuator 140 extends the lift base 182 to a position beyond the approximate expected position of the end of the loading drawer positioning tab 276. The conveyor 120 is then lowered in steps until the lift base 180 contacts the positioning tab 276. Contact between the lift base 180 and the positioning tab 276 can be detected in several ways, such as by capacitance or by completing a circuit that generates a contact signal when contact occurs between the lift base and the positioning tab 276. Alternatively, contact can be determined by the load on the lifter drive motor 212 increasing beyond a specified threshold when the conveyor lift 210 attempts to continue lowering the lift base 180 after the lift base has contacted the positioning tab 276. Alternatively, contact between the lift frame 180 and the positioning tab 276 can be detected by detecting motor stall by comparing the commanded motor step with the encoder position.

[0224] In another embodiment, the conveyor 120 is positioned by the conveyor lift 210 at a height known to be below the approximate expected position of the loading drawer 280 (or below the approximate position of the loading drawer positioning tab 276), and then the scissors actuator 140 extends the lift base 182 to a position beyond the approximate expected position of the end of the loading drawer positioning tab 276. The conveyor 120 is then raised in steps until the lift base 180 contacts the positioning tab 276. Contact between the lift base 180 and the positioning tab 276 can be detected in several ways, such as by capacitance or by completing a circuit that generates a contact signal when contact occurs between the lift base and the positioning tab 276. Alternatively, contact can be determined by the load on the lifter drive motor 212 increasing beyond a specified threshold when the conveyor lift 210 attempts to continue raising the lift base 180 after the lift base has contacted the positioning tab 276. Alternatively, contact between the lift frame 180 and the positioning tab 276 can be detected by detecting motor stall by comparing the commanded motor step with the encoder position.

[0225] In another embodiment, the conveyor 120 is positioned by the conveyor lift 210 at a height known to be approximately where the loading drawer 280 is located. The scissors actuator 140 then extends the lift base 182 until it contacts the end of the loading drawer positioning tab 276, or until the lift base moves beyond a predetermined lateral distance without contacting the loading drawer positioning tab 276. When the scissors actuator 140 extends the lift base 182 beyond a predetermined lateral distance without contacting the loading drawer positioning tab 276, the scissors actuator retracts the lift base 180, and the conveyor lift 210 adjusts the height of the conveyor 120 upward or downward, and the scissors actuator 140 extends the lift base 182 until the lift base 182 contacts the end of the loading drawer positioning tab 276 or the lift base moves beyond a predetermined lateral distance without contacting the loading drawer positioning tab 276. This process is repeated iteratively until the lift base 182 contacts the end of the loading drawer positioning tab 276. Contact between the lift base 180 and the loading drawer positioning tab 276 can be detected in several ways, such as by capacitance or by completing a circuit that generates a contact signal when contact occurs between the lift base and the positioning tab 276. Alternatively, contact may be determined by the load on the scissors drive motor 192 increasing beyond a specified threshold when the scissors actuator 140 attempts to continue moving the lift base 180 laterally after the lift base has made contact with the positioning tab 276. Alternatively, contact between the lift base 180 and the positioning tab 276 may be detected by detecting motor stall by comparing the commanded motor step with the encoder position.

[0226] After step 504, in step 506, the vertical position of the conveyor 120 and the lateral extension of the lift frame 180 when the loading drawer positioning tab 276 is in contact with the lift frame 180 are recorded and stored for future reference when positioning the frame 180 with respect to the loading drawer 280.

[0227] In an alternative embodiment, the self-repair process for the loading drawer 280 is performed by contacting a positioning structure other than the positioning tab 276, such as a portion of the loading drawer 280 or some other protruding structure at a known position relative to the holding shelf loading drawer 280.

[0228] In step 508, the conveyor 120 is moved by the conveyor lifter 210 to a position adjacent to the expected position of the holding shelf 104. In step 510, the holding shelf positioning tab 108 is brought into contact with the lift base 180. The processor controls the contact between the lift base 180 and the holding shelf positioning tab 108 in one of the above-described methods for controlling contact with the loading drawer positioning tab 276.

[0229] After step 510, in step 512, the vertical position of the conveyor 120 and the lateral extension of the lift frame 180, to which the retaining shelf positioning tab 108 is in contact with the lift frame 180, are recorded and stored for future reference when positioning the frame 180 relative to the retaining shelf 104.

[0230] In step 514, steps 508 to 512 are repeated for all holding shelves 104.

[0231] In an alternative embodiment, the self-repair process for each of the retaining shelves 104 is performed by contacting a positioning structure other than the positioning tab 108, such as a portion of the retaining shelf 104 or some other protruding structure at a known position relative to the retaining shelf 104.

[0232] In step 516, the conveyor 120 is moved by the conveyor lift 210 to a position adjacent to the expected position of the input module 230. In step 518, the input module positioning tab 256 is brought into contact with the lift base 180. The processor controls the contact between the lift base 180 and the input module positioning tab 256 in one of the above-described methods for controlling contact with the loading drawer positioning tab 276.

[0233] After step 518, in step 520, for future reference when positioning the lift frame 180 relative to the input module 230, the vertical position of the conveyor 120 and the lateral extension of the lift frame 180 are recorded and stored when the input module positioning tab 256 is in contact with the lift frame 180.

[0234] In an alternative embodiment, the self-repair process for the input module 230 is performed by bringing a positioning structure other than the positioning tab 256, such as a portion of the input module 230 or some other protruding structure, into contact with the holding shelf input module 230 at a known position.

[0235] Embodiment Embodiment 1. A device for transporting a collection of consumables between a plurality of vertically spaced holding shelves, A support chassis positioned at lateral spacing relative to multiple holding shelves, A transport elevator coupled to the support chassis for vertically moving the support chassis between multiple holding shelves, Lift platform and A device comprising: a lift frame connected to a support chassis; and a scissors actuator configured to laterally translate the lift frame relative to the support chassis between a first position laterally aligned with the support chassis at a laterally spaced position relative to a plurality of holding shelves, and a second position laterally displaced from the support chassis and laterally aligned with one of the holding shelves.

[0236] Embodiment 2. The apparatus according to Embodiment 1, further comprising a transport body that is transported on a lift platform and configured to be arranged on one of a plurality of holding shelves.

[0237] Embodiment 3. The apparatus according to Embodiment 2, wherein the carrier comprises a base, a pair of support rails for slidably supporting consumables thereon, and elastic tabs located at the ends of each support rail and configured to releasely hold consumables on the support rails.

[0238] Embodiment 4. The apparatus according to Embodiment 3, wherein each elastic tab is attached to a portion of its respective support rail or is located at the end of an adjacent meandering spring.

[0239] Embodiment 5. The transport elevator is Two drive belts, each drive belt attached to a part of the support chassis, Drive gears for each drive belt, A motor coupled to a drive gear and The apparatus according to any one of embodiments 1 to 4, comprising idler gears for each drive belt.

[0240] Embodiment 6. The apparatus according to any one of Embodiments 1 to 5, further comprising an elevator home sensor configured to detect a locator flag extending from a support chassis.

[0241] Embodiment 7. The apparatus according to any one of Embodiments 1 to 6, wherein the scissors actuator comprises a first arm having a first end and a second end, and a second arm having a first end and a second end, the first arm and the second arm being rotatably connected to each other at an intermediate position between their respective first and second ends, the first arm being pivotably mounted to a support chassis at its first end and pivotably and translatably mounted to a lift frame at its second end, and the second arm being pivotably and translatably mounted to a support chassis at its first end and pivotably mounted to a lift frame at its second end.

[0242] Embodiment 8. The apparatus according to Embodiment 7, wherein a first arm and a second arm are rotatably connected to each other by a swivel ring having an inner ring and an outer ring, the inner ring and the outer ring being rotatable relative to each other, the first arm being attached to the inner ring at its respective intermediate position, and the second arm being attached to the outer ring at its respective intermediate position.

[0243] Embodiment 9. The apparatus according to Embodiment 7 or Embodiment 8, wherein the second end of the first arm is pivotably and translatably attached to the lift frame by a sliding body slidably disposed in a linear slot formed in the lift frame, and the sliding body is rotatably attached to the second end of the first arm.

[0244] Embodiment 10. The apparatus according to Embodiment 9, further comprising rolling bearings disposed within the sliding body that roll against the side surface of the slot during the lateral translation of the lift frame.

[0245] Embodiment 11. The apparatus according to any one of embodiments 8 to 10, wherein the scissors actuator further comprises a motor coupled to the first end of the first arm for powered pivoting motion of the first arm.

[0246] Embodiment 12. The apparatus according to any one of Embodiments 1 to 11, wherein the scissors actuator is configured to translate the lift carriage in either of two opposite lateral directions with respect to the support chassis.

[0247] Embodiment 13. The apparatus according to any one of Embodiments 1 to 12, further comprising a carrier detection sensor associated with each holding shelf and configured to detect the presence of a carrier on the associated holding shelf.

[0248] Embodiment 14. An apparatus, a plurality of vertically spaced holding shelves, a transporter for transporting an aggregate of consumables between the plurality of holding shelves, a support chassis disposed at a position laterally spaced from the plurality of holding shelves, a lift carriage, a scissors actuator that connects the lift carriage to the support chassis and is configured to translate the lift carriage laterally with respect to the support chassis between a first position laterally aligned with the support chassis at a position laterally spaced from the plurality of holding shelves and a second position laterally aligned with one of the holding shelves and laterally displaced from the support chassis, a transport elevator coupled to the support chassis for vertically moving the support chassis between the plurality of holding shelves.

[0249] Embodiment 15. The apparatus according to Embodiment 14, further comprising a carrier configured to hold a consumable, be transported on the lift carriage, and be arranged on any one of the plurality of holding shelves.

[0250] Embodiment 16. The apparatus according to Embodiment 15, wherein each holding shelf includes a carrier detection sensor configured to detect the presence of a carrier on the corresponding holding shelf.

[0251] Embodiment 17. The apparatus according to Embodiment 15 or 16, wherein the carrier includes a base, a pair of support rails for slidably supporting a consumable thereon, and elastic tabs located at ends of each support rail and configured to releasably hold the consumable on the support rail.

[0252] Embodiment 18. The apparatus according to Embodiment 17, wherein each elastic tab is attached to its respective support rail or is disposed at an end of a serpentine spring that is a part thereof.

[0253] Embodiment 19. The apparatus according to any one of Embodiments 15 to 18, wherein the carrier includes at least one opening formed in its bottom, and each holding shelf includes at least one carrier locator pin that protrudes from the holding shelf to engage with the opening formed in the carrier.

[0254] Embodiment 20. The conveying elevator includes two drive belts, each drive belt being attached to a part of the support chassis, the drive belts, drive gears for each drive belt, a motor coupled to the drive gears, and idler gears for each drive belt, and is the apparatus according to any one of Embodiments 14 to 17.

[0255] Embodiment 21. The apparatus according to any one of Embodiments 14 to 20, wherein one of the holding shelves includes a carrier support configured to be movable laterally between a first position accessible by a conveyor and a second position accessible by a user for loading consumables onto the carrier supports of a plurality of carriers.

[0256] Embodiment 22. The apparatus according to Embodiment 14, further comprising a carrier that is transported on a lift platform and configured to be arranged in one of a plurality of holding shelves, one of the holding shelves having a carrier support configured to be laterally movable between a first position accessible by a conveyor for loading a plurality of consumables into the carrier support and a second position accessible by a user, and the carrier support having a carrier locking mechanism configured to lock the carrier within the carrier support when the carrier support is moved to the second position and to release the carrier when the carrier support is moved to the first position, thereby allowing the conveyor to remove the carrier from the carrier support.

[0257] Embodiment 23. The transport body locking mechanism is A pivoting latch configured to pivot between a first position in which it does not engage with a portion of the transport body and a second position in which it engages with a portion of the transport body, The apparatus according to embodiment 22, comprising a sliding latch configured to translate linearly between a first position in which it does not engage with a portion of the transport body and a second position in which it engages with a portion of the transport body.

[0258] Embodiment 24. A torsion spring coupled to the pivot latch for biasing the pivot latch to each second position that engages with a portion of the carrier, The apparatus according to embodiment 23, comprising: a linear spring coupled to a sliding latch for biasing the sliding latch to each second position in which it engages with a portion of a carrier.

[0259] Embodiment 25. The pivot latch includes an upper end that engages with a portion of the carrier on the carrier support when the carrier support is in a second position and the pivot latch is in a second position, and a lower end that contacts a hard stop when the carrier support is moved from its second position to its first position, thereby rotating the pivot latch from the second position to the first position, thereby releasing the carrier supported on the carrier support. The apparatus according to Embodiment 23 or Embodiment 24, wherein the sliding latch engages with a portion of the carrier on the carrier support when the carrier support is in a second position, and when the carrier support is moved from its second position to its first position, the sliding latch contacts a hard stop that pushes the sliding latch to the first position, thereby releasing the carrier supported on the carrier support.

[0260] Embodiment 26. The transporter is longer than the lift frame such that the first and second ends of the transporter extend beyond the first and second ends of the lift frame, and each holding shelf has a first shelf portion and a second shelf portion spaced at least the length of the lift frame, and the conveyor is, a) The lifting mechanism moves the support chassis to a vertical position above the holding shelf, b) Moving the lift frame laterally by a scissors actuator to a position where the first and second ends of the transport body are aligned with the first and second shelf portions of the holding shelf, c) The apparatus according to any one of embodiments 15 to 19, configured and controlled to transport a transport supported on a lift frame from a lift frame to one of a plurality of holding shelves by moving a lift frame between the first and second shelf portions, by lowering a support chassis by a transport lift until the first and second ends of the transport body are supported on the first and second shelf portions.

[0261] Embodiment 27. The apparatus according to Embodiment 14, wherein each consumable comprises a multi-receiver unit including a plurality of receivers arranged in parallel and connected to one another, the apparatus further comprises a carrier configured to be transported on a lift frame and arranged on one of a plurality of holding shelves, the carrier comprising a base, a pair of parallel support rails for slidably supporting the multi-receiver unit thereon with at least one of the receivers of the multi-receiver unit positioned between support rails, and elastic tabs located at the ends of each support rail and configured to releasably hold the multi-receiver unit on the support rails, one of the holding shelves comprising an input module configured to hold the carrier therein, the input module comprising an extruder configured to push one or more multi-receiver units supported on the carrier toward the end of the carrier.

[0262] Embodiment 28. The apparatus according to Embodiment 27, wherein the input module is located on one side of the support chassis, one or more of the remaining holding shelves are located on the opposing side of the support chassis, and the scissors actuator is configured to translate the lift frame laterally to either of the two opposing sides of the support chassis.

[0263] Embodiment 29. The apparatus according to Embodiment 14, wherein each consumable comprises a multi-receiver unit including a plurality of receivers arranged in parallel and connected to one another, the apparatus further comprises a carrier configured to be transported on a lift frame and arranged on one of a plurality of holding shelves, the carrier comprising a base, a pair of parallel support rails for slidably supporting a multi-receiver unit thereon, the pair of parallel support rails positioned between at least one of the receivers of each multi-receiver unit, and stop flanges located at the ends of each support rail.

[0264] Embodiment 30 The apparatus of Embodiment 29, wherein at least one of the holding shelves is configured to move relative to a transport body held on the holding shelf and to push the transported multi-receiving unit on the transport body until one of the final ends of the multi-receiving unit is pushed out from the support rail.

[0265] Embodiment 31. The apparatus according to Embodiment 30, further comprising a packaging mechanism position sensor configured to detect the stopping position of a packaging mechanism in which one of the outermost of the multiple receiver units is pushed out from a support rail, and to determine the number of multiple receiver units to be transported on the transport body based on the detected stopping position.

[0266] Embodiment 32. A position sensor mechanism for detecting the vertical position of the support chassis and the lateral position of the lift frame, It comprises a control unit for controlling the transport elevator and scissor actuator and communicating with the position sensor mechanism, The apparatus according to any one of embodiments 14 to 31, wherein the control unit is configured to record the position of each holding shelf by moving the lift base relative to each holding shelf until the lift base contacts the positioning tab of the holding shelf, and by recording the vertical position of the support chassis and the lateral position of the lift base detected by a position sensor mechanism when the lift base contacts the positioning tab.

[0267] Embodiment 33. A carrier support for holding a carrier, wherein the carrier is configured to hold a plurality of receivers, the carrier support is configured to be movable between a first position and a second position, and the carrier support includes a carrier locking mechanism configured to lock the carrier to the carrier support when the carrier support is moved to the second position, and to release the carrier when the carrier support is moved to the first position, so that the carrier support can move relative to the carrier support when it is in the first position, the carrier locking mechanism is, A pivoting latch configured to pivot between a first position in which it does not engage with a portion of the transport body and a second position in which it engages with a portion of the transport body, A carrier support comprising a sliding body latch configured to linearly translate between a first position that does not engage a portion of the carrier and a second position that engages a portion of the carrier.

[0268] Embodiment 34. A torsion spring coupled to the pivot latch for biasing the pivot latch to each second position where it engages a portion of the carrier. The carrier support according to Embodiment 33, further comprising a linear spring coupled to the sliding body latch for biasing the sliding body latch to each second position where it engages a portion of the carrier.

[0269] Embodiment 35. The pivot latch includes an upper end that engages a portion of the carrier on the carrier support when the carrier support is in the second position and the pivot latch is in the second position, and a lower portion that contacts a hard stop when the carrier support is moved from its second position to its first position. Thus, the pivot latch rotates from the second position to the first position, thereby releasing the carrier supported by the carrier support. The sliding body latch engages a portion of the carrier on the carrier support when the carrier support is in the second position and the sliding body latch is in the second position, and when the carrier support is moved from its second position to its first position, the sliding body latch contacts a hard stop that pushes the sliding body latch into the first position, thereby releasing the carrier supported on the carrier support. The carrier support according to Embodiment 33 or Embodiment 34.

[0270] Embodiment 36. A carrier shelf for receiving and supporting a carrier holding a plurality of receivers. An input module comprising a recovery dock adjacent to the carrier shelf, configured to receive one receiver from the carrier supported by the carrier shelf and provide the receiver for removal from an input module by a receiver transport device. An extruder configured to push one or more receivers held by the carrier supported by the carrier shelf into one end of the carrier and push out one receiver at a time from the end of the carrier into the recovery dock.

[0271] Embodiment 37. The extruder is An extruder carriage, coupled to an extruder track and configured to translate bidirectionally along the track, An input module according to embodiment 36, including an extruder arm protruding from the extruder carriage.

[0272] Embodiment 38. The extruder arm is A support column extending upward from the extruder carriage, A lateral portion extending horizontally from the end of the support column, The input module according to embodiment 37, comprising a contact portion extending downward from a lateral portion.

[0273] Embodiment 39. An input module according to Embodiment 38, wherein a carrier supported on a carrier shelf includes a pair of parallel support rails for slidably supporting a plurality of receivers thereon, and at least a portion of each receiver is positioned between the support rails, and the contact portion is aligned in the gap between the support rails such that the contact portion moves between the support rails and contacts a portion of the receiver positioned between the support rails as the extruder translates along the extruder track.

[0274] Embodiment 40. An input module according to Embodiment 39, wherein the receiver comprises a plurality of cylindrical tubes connected to one another by a connecting rib structure defining downward shoulders, at least one of the cylindrical tubes is positioned between a support rail and a portion thereof, and the portion of the downward shoulder is supported at the top of the support rail.

[0275] Embodiment 41. The extruder is The extruder drive belt attached to the extruder carriage, An input module according to any one of embodiments 37 to 40, comprising an extruder motor coupled to an extruder drive belt for providing powered translation of the extruder carriage along the extruder track.

[0276] Embodiment 42. An input module according to any one of embodiments 36 to 41, further comprising a sensor configured to detect when one of the receivers is pushed into a retrieval dock.

[0277] Embodiment 43. An input module according to any one of embodiments 36 to 42, further comprising a guide plate adjacent to the recovery dock and configured to align the receiver on the recovery dock with the receiver transport device.

[0278] Embodiment 44. An input module according to any one of embodiments 36 to 43, further comprising at least one carrier locator pin protruding from the carrier shelf to engage with an opening formed in a carrier supported by the carrier shelf and to restrict relative movement between the carrier shelf and the carrier supported by it.

[0279] Embodiment 45. A position encoder for detecting the longitudinal position of an extruder, An input module according to any one of embodiments 36 to 44, further comprising: a control unit configured to receive longitudinal position data from a position encoder and determine the number of receivers held on a carrier supported on a carrier shelf when the extruder is positioned in contact with the last receiver of one or more receivers held on the carrier.

[0280] Embodiment 46. An input module according to any one of embodiments 36 to 45, further comprising an extruder home sensor configured to detect when the extruder has moved to a home position.

[0281] Embodiment 47. An input module described in any one of Embodiments 36 to 46, A processing device comprising a receiver transport device configured to retrieve a receiver from the input module's retrieval dock and transport the receiver within the processing device.

[0282] Embodiment 48. A carrier for holding multiple multiple receiver units, each multiple receiver unit comprising multiple receivers arranged in parallel and connected to one another, the carrier is A pair of parallel support rails for slidably supporting a multi-receiver unit, with at least one of the receivers of the multi-receiver unit positioned between the support rails, A carrier comprising: elastic tabs associated with each support rail and configured to releasably hold multiple receiver units on the support rails.

[0283] Embodiment 49. The carrier according to Embodiment 48, wherein each elastic tab is located at the end of a meandering spring.

[0284] Embodiment 50. The carrier according to Embodiment 49, wherein each serpentine spring is an integral part of each associated support rail.

[0285] Embodiment 51. A carrier according to any one of Embodiments 48 to 50, wherein the support rail is made of spring steel.

[0286] Embodiment 52. A carrier according to any one of Embodiments 48 to 51, further comprising a carrier base having a first end, a second end, and a connecting portion extending between the first end and the second end, wherein the connecting portion is usually narrower than the first end and the second end.

[0287] Embodiment 53. The transporter according to Embodiment 52, wherein the support rail is attached to the opposing edges of the connection portion.

[0288] Embodiment 54. A carrier according to any one of embodiments 48 to 51, further comprising a carrier base having one or more locator holes formed at the bottom of the carrier base.

[0289] Embodiment 55. The carrier according to Embodiment 54, further comprising a locator hole at a first end of the carrier base and a locator slot at a second end of the carrier base.

[0290] Embodiment 56. The carrier according to Embodiment 54 or Embodiment 55, further comprising two locator holes at the first end of the carrier base and two locator slots at the second end of the carrier base.

[0291] Embodiment 57. A scissors actuator configured to translate a support frame in either the lateral direction opposite to the base frame, A first arm having a first end and a second end, A second arm having a first end and a second end, wherein the first arm and the second arm are rotatably connected to each other at an intermediate position between their respective first and second ends, and the first arm is pivotably attached at its first end to a base frame and the second arm, and the second arm is pivotally attached at its second end to a support frame, A first sliding body, which includes a bearing that is positioned within a first linear track formed in a support frame and protrudes from the side of a first sliding body to make rolling contact with the side of the first linear track formed in the support frame, wherein a first arm is pivotably and translationally attached to the support frame at a second end by the first sliding body, A scissors actuator comprising: a second sliding body including a bearing that is positioned within a second linear track formed in a base frame and protrudes from the side of a second sliding body to make rolling contact with the side of the second linear track formed in the base frame, wherein a second arm is attached to the base frame at its first end by the second sliding body so as to be translationally and pivotally movable.

[0292] Embodiment 58. The scissors actuator according to Embodiment 57, wherein a first arm and a second arm are rotatably connected to each other by a swivel ring having an inner ring and an outer ring, the inner ring and the outer ring being rotatable relative to each other, the first arm being attached to the inner ring at its respective intermediate position, and the second arm being attached to the outer ring at its respective intermediate position.

[0293] Embodiment 59. The scissors actuator according to Embodiment 57 or Embodiment 58, further comprising a motor coupled to the first end of the first arm for providing a powered pivoting motion of the first arm.

[0294] Embodiment 60. The scissors actuator according to Embodiment 59, further comprising a motor or an encoder coupled to a first arm.

[0295] Embodiment 61. A scissors actuator according to any one of embodiments 57 to 60, wherein the scissors actuator is configured to translate the support frame in one of two opposing lateral directions relative to the base frame.

[0296] Embodiment 62. A method for automatically transferring a receiving transporter between a holding shelf and a lift frame of a conveyor, a) Using a conveyor lift to bring the conveyor up vertically, position the conveyor at an approximate vertical position on the holding shelf, b) After step a), bring about relative movement between the lift frame and the positioning structure associated with the holding shelf, c) During step b), detect contact between the lift base and the positioning structure, d) Record data regarding the position of the lift platform where contact was detected in step c), e) A method comprising transferring a receiving carrier between a holding shelf and a lift stand by controlling the movement of the lift stand according to the data recorded in step d).

[0297] Embodiment 63. The method according to Embodiment 62, wherein step b) includes one or both of the following: (1) providing vertical movement of the lift base relative to the holding shelf by a conveyor lifter, and (2) providing lateral movement of the lift base by a lateral actuator.

[0298] Embodiment 64. Step a) includes positioning the conveyor such that the vertical position of the lift base is lower than the expected vertical position of the positioning structure, and step b) is b-1) Move the lift platform laterally using a lateral actuator until the lift platform is positioned below the expected position of the positioning structure, b-2) The method according to embodiment 63, wherein after step b-1), the conveyor and lift platform are raised by the conveyor lift until contact is detected in step c).

[0299] Embodiment 65. Step a) includes positioning the conveyor such that the vertical position of the lift base is above the expected vertical position of the positioning structure, and step b) is b-1) The lift base is moved laterally by a lateral actuator until it is positioned above the expected position of the positioning structure. b-2) The method according to embodiment 63, wherein after step b-1), the conveyor and the lift base are lowered by the conveyor lift until contact is detected in step c).

[0300] Embodiment 66. The method according to Embodiment 63, wherein step a) includes positioning the conveyor such that the vertical position of the lift base is the same as the expected vertical position of the positioning structure, and step b) includes moving the lift base laterally by a lateral actuator until contact is detected in step c).

[0301] Embodiment 67. Step e) is, The receiving and transporting body is supported on the lift frame in a state where opposing ends of the receiving and transporting body extend beyond the opposing ends of the lift frame, The conveyor lift uses the data recorded in step d) to position the conveyor vertically so that the lift platform is above the holding shelf, Lateral movement of the lift platform is brought about by a lateral actuator, and using the data recorded in step d), the lift platform is positioned within the open area between the opposing ends of the first and second shelf portions of the holding shelf, and the opposing ends of the receiver transport are positioned above the first and second shelf portions. The method according to any one of embodiments 62 to 66, comprising transferring the receiving transport from the lifting platform to the holding shelf by a transporter lifting device, wherein both ends of the receiving transport are supported by a first shelf portion and a second shelf portion, and the lifting platform is lowered until the receiving transport is no longer supported by the lifting platform.

[0302] Embodiment 68. Step e) is, The first and second shelf portions of the holding shelf support the opposing ends of the receiving and carrying body, The conveyor lift uses the data recorded in step d) to position the conveyor vertically so that the lift platform is below the holding shelf, Lateral actuators are used to cause lateral movement of the lift platform, and the data recorded in step d) is used to align the lift platform with the open area between the first shelf section and the second shelf section. The method according to any one of embodiments 62 to 66, comprising: transporting the receiving carrier from a holding shelf to a lifting platform by a transporter lifting device, wherein the receiving carrier is supported on the lifting platform such that both ends of the receiving carrier extend beyond the opposite end of the lifting platform, and raising the lifting platform until both ends of the receiving carrier are raised from the first shelf portion and the second shelf portion.

[0303] Embodiment 69. A method for determining the number of receivers supported by a carrier, a) Arranging the carriers supported by one or more receivers on a carrier shelf, b) With the packaging machine positioned adjacent to the transport shelf, one or more receivers are pushed into one end of the transport body, c) When one or more receivers are pushed into one end of the transport body, the longitudinal position of the packaging machine is detected, d) A method comprising determining the number of receivers to be held in the carrier based on the longitudinal position of the packaging machine.

[0304] Embodiment 70. Step a) is, The transport body is supported on the lift platform with both ends of the transport body extending beyond both ends of the lift platform, The lift platform is positioned above the transport shelf using a transport lifting device, Lateral movement of the lift frame is brought about by a lateral actuator so that the lift frame is positioned in the open area between the first and second shelf sections of the transport shelf, and the opposing ends of the transport are positioned above the first and second shelves. The method according to embodiment 69, comprising lowering the lifting platform until both ends of the transported body are supported by the first and second shelf portions and the transported body is no longer supported by the lifting platform, thereby transferring the transported body from the lifting platform to the transported body shelf.

[0305] Embodiment 71. The packaging machine is A ballast carriage, configured to be coupled to the ballast track and to move bidirectionally along the track, The contact portion protruding from the packaging machine carriage, The packing machine drive belt attached to the packing machine carriage, The method according to Embodiment 69 or Embodiment 70, further comprising a ballast motor coupled to a ballast drive belt for powered translation of the ballast carriage along the ballast track.

[0306] Embodiment 72. The method according to Embodiment 71, wherein step c) includes detecting the output of the packaging machine motor by a rotary encoder coupled to the packaging machine motor, or detecting the output of the packaging machine motor by a motor step.

[0307] Embodiment 73. A method for packaging a plurality of receivers supported by a carrier, a) Arranging a carrier equipped with multiple receivers supported thereby on a carrier shelf, b) one of the final ends of the receivers is brought into contact with a packaging machine positioned adjacent to the transport shelf, wherein the packaging machine includes a packaging machine carriage coupled to a packaging machine track and configured to translate bidirectionally along the track, and a contact portion protruding from the packaging machine carriage. c) A method comprising using a packaging machine to push multiple receivers into one end of a transport body and packaging the receivers within a stacking section.

[0308] Embodiment 74. The method according to Embodiment 73, wherein a carrier supported on a carrier shelf includes a pair of parallel support rails for slidably supporting a plurality of receivers thereon, and at least a portion of each receiver is positioned between the support rails, and step c) brings the packaging machine and one of the final ends of the receivers into contact by aligning a contact portion with the gap between the support rails, thereby causing the contact portion to move between the support rails and into contact with the portion of the final end receiver positioned between the support rails as the packaging machine carriage translates along the packaging machine track.

[0309] Embodiment 75. The method according to Embodiment 74, wherein the transport body includes hard stops at the ends of each support rail, and step c) includes pushing a plurality of receivers against the hard stops.

[0310] Embodiment 76. The method according to Embodiment 74 or Embodiment 75, wherein the receiver comprises a plurality of cylindrical tubes connected to one another by a connecting rib structure defining downward shoulders, at least one of the cylindrical tubes is positioned between support rails, and the downward shoulders are supported on the upper part of the support rails.

[0311] Embodiment 77. The method according to Embodiment 76, further comprising a horizontal portion which contacts a portion of the final end receiver extending over a support rail, thereby keeping the receiver substantially perpendicular to the longitudinal direction of the support rail.

[0312] Embodiment 78. The packaging machine is The packing machine drive belt attached to the packing machine carriage, The method according to any one of embodiments 73 to 77, further comprising a ballast motor coupled to a ballast drive belt for powered translation of the ballast carriage along the ballast track.

[0313] Embodiment 79. During step c), the longitudinal position of the packaging machine is detected, A method according to any one of embodiments 73 to 77, further comprising determining the number of receivers to be held in the carrier based on the longitudinal position of the packaging machine.

[0314] Embodiment 80. The method according to Embodiment 79, wherein the packaging machine further comprises a packaging machine drive belt attached to a packaging machine carriage and a packaging machine motor coupled to the packaging machine drive belt for powered translation of the packaging machine carriage along a packaging machine trajectory, and detecting the longitudinal position of the packaging machine during step c) further includes using a home sensor to detect the initial position of the packaging machine along the packaging machine trajectory and using an encoder coupled to the packaging machine motor to detect a number of encoder counts related to the movement of the electric packaging machine from the initial position along the packaging machine trajectory.

[0315] Embodiment 81. A method for providing a multiple receiver unit for collection by an automatic receiver distributor of processing equipment, wherein each multiple receiver unit includes a plurality of receivers arranged in parallel and connected to each other, and this method a) Arranging a carrier on a carrier shelf, wherein one or more multi-receiving units are held thereon, and the carrier comprises a pair of parallel support rails for slidably supporting the multi-receiving units thereon, and at least one of the receivers of each multi-receiving unit is positioned between the support rails. b) Contacting one of the final ends of the receivers with an extruder positioned adjacent to a transport shelf, wherein the extruder has a contact portion configured to move between support rails and contact receivers positioned between support rails, c) A method comprising using an extruder to push multiple multiple receiver units along a support rail toward one end of a carrier until one of the final ends of the multiple receiver units is pushed out from the support rail and pushed into a retrieval dock adjacent to the carrier shelf.

[0316] Embodiment 82. Detection that one of the multiple receiver units has been removed from the support rail and pushed into the recovery dock, The method according to embodiment 81, further comprising stopping the extruder from further pushing one or more multiple receiving units toward one end of the conveyor.

[0317] Embodiment 83. The method according to Embodiment 81 or Embodiment 82, further comprising retrieving one multiple receiver unit from a retrieval dock by a receiver transport mechanism of a processing device.

[0318] Embodiment 84. The method according to Embodiment 83, wherein the receiver transport mechanism includes an extendable hook, the multiple receiver unit comprises an operating structure, and the retrieval of one receiver from the retrieval dock by the receiver transport mechanism includes extending the hook, engaging the operating structure with the extended hook, and retracting the hook to pull the multiple receiver unit from the retrieval dock into the housing of the receiver transport mechanism.

[0319] Embodiment 85. During step c), the longitudinal position of the extruder is detected when the multiple receiver unit is pushed out from the support rail, The method according to any one of embodiments 81 to 84, comprising determining the number of multiple receiver units held in the carrier based on the longitudinal position of the extruder.

[0320] Embodiment 86. Step a) is, The transport body is supported on the lift platform with both ends of the transport body extending beyond both ends of the lift platform, The lift platform is positioned above the transport shelf using a transport lifting device, Lateral movement of the lift frame is brought about by a lateral actuator so that the lift frame is positioned in the open area between the first and second shelf sections of the transport shelf, and the opposing ends of the transport are positioned above the first and second shelves. The method according to any one of embodiments 81 to 85, comprising lowering the lifting platform until both ends of the transport body are supported by the first and second shelf portions and the transport body is no longer supported by the lifting platform, thereby transferring the transport body from the lifting platform to the transport body shelf.

[0321] Embodiment 87. An extruder carriage configured to be coupled to an extruder track and to translate bidirectionally along the track, An extruder arm having a contact portion and protruding from the extruder carriage, The extruder drive belt attached to the extruder carriage, The method according to any one of embodiments 81 to 86, further comprising: an extruder motor coupled to an extruder drive belt for powered translation of the extruder carriage along the extruder track.

[0322] Embodiment 88. The method according to any one of embodiments 81 to 87, further comprising, before step c), securing one or more multiple receiver units on a support rail having a spring-biased retaining tab that releasably engages with one of the final ends of the multiple receiver units, wherein the spring-biased retaining tab is configured to deflect laterally during step c) so as to allow one of the final ends of the multiple receiver units to be pushed off the support rail.

[0323] While the subject matter of this disclosure is described and illustrated in considerable detail, including various combinations and partial combinations of features, with reference to an illustrative embodiment, those skilled in the art will readily understand other embodiments and variations thereof that are included within the scope of this disclosure. Furthermore, the description of such embodiments, combinations, and partial combinations is not intended to convey that the subject matter described in the claims requires any features or combinations of features other than those expressly enumerated in the claims. Accordingly, the scope of this disclosure shall include all modifications and variations that are included within the following appended claims.

Claims

[Claim 1] The invention as described in the drawings of the present application.

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