Phase activation to drive carrier and measure back-emf

Abstract

A vessel transport system in a liquid handler system utilizes inactive coils to collect back EMF information about magnets in a vessel mover. A vessel mover is configured to transport a sample vessel and has a magnetic base. A track comprising an n-phase drive is configured to provide selective magnetic fields to propel the magnetic base of the vessel mover along the track. Each phase is configured to provide current to one of a plurality of coils comprising n coils. A processor is configured to control selective application of currents to the track using n-1 coils, with the remaining coil being inactive to measure back EMF. The processor uses the measurements to determine the vessel mover's position and velocity.

Description

PHASE ACTIVATION TO DRIVE CARRIER AND MEASURE BACK-EMFCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 550,343, entitled ‘PHASE ACTIVATION TO DRIVE CARRIER AND MEASURE BACK-EMF” filed February 6, 2024, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.BACKGROUND

[0002] Liquid handlers are robotic systems that are designed to dispense and process selected quantities of reagents, samples, or other liquids. Some liquid handlers are additionally adapted to analyze samples using, for example, immunoassay and / or clinical chemistry techniques. Such types of liquid handlers could be referred to as “analyzers’' or “analyzer systems.” Some liquid handlers can include a number of modules (also referred to as stations) and a transport system to move samples between the various modules. It is highly desirable for the liquid handler transport systems to move the sample containers in a smooth manner, avoid causing the sample containers to collide with each other and, otherwise prevent liquids from spilling from their containers during transport. In particular, liquid spills waste reagents and / or samples (which could potentially impact the integrity of any tests being performed) and if the spill occurs on the track, it can also create obstructions that could negatively impair the movement of subsequent sample containers.

[0003] Liquid handlers are often used in in vitro diagnostics (IVD) applications. IVD allows labs to assist in the diagnosis of disease based on assays performed on patient fluid samples. IVD includes various types of analytical tests and assays related to patient diagnosis and therapy that can be performed by analysis of a liquid sample taken from a patient's bodily fluids, or abscesses. These assays are typically conducted with automated clinical chemistry analyzers onto which fluid containers, such as tubes or vials, containing patient samples have been loaded. The analyzer extracts a liquid sample from the vial and combines the sample with various reagents in special reaction cuvettes or tubes (referred to, generally, as reaction vessels). In some conventional systems, a modular approach is used for analyzers. A lab automation system can shuttle samples between one sample processing module (module) and another module. Modules may include one or more stations, including sample handling stations and analyzer modules / testing stations (e.g., a unit that can specialize in certain t pes of assays), or can otherwise provide testing services to the larger analyzer, which may include immunoassay (IA) and clinical chemistry (CC) stations, or any other element in the IVDprocess flow, such as centrifuges, decappers, refrigerated storage, sealers / de-sealers, and sample integrity stations. Some traditional IVD automation track systems comprise systems that are designed to transport samples from one fully independent module to another standalone module. This allows different types of tests to be specialized in two different stations / modules or allows two redundant stations to be linked to increase the volume of sample throughput available. These lab automation systems, however, are often bottlenecks in multi-station analyzers. Relatively speaking, traditional lab automation systems lack large degrees of intelligence or autonomy to allow samples to independently move between stations. Moreover, lab automation systems can be expensive due to their size and complexity.

[0004] Conventional liquid handler systems track vessel movers and the liquid samples carried thereby throughout the track systems interconnecting the modules using mechanical conveyor systems (e.g., belts). Recently, there has been some development using coils embedded in the track surface to propel one or more magnets in the base of a vessel mover, the coils and the magnet in the vessel mover together forming a linear synchronous motor (LSM). In an LSM, coils in the track are selectively activated to selectively apply a magnetic field to magnets in the vessel movers, synchronizing the fields to the movement of the magnets, causing movement along a plane. Conventionally, the coils are made of narrowgauge wound copper wire. This approach is simple to construct, but is expensive, especially as the number of coils goes up to accommodate a large number of paths and the overall size of a laboratory automation system. Furthermore, drive circuits are needed for the coils and Hall effect sensors need to be placed near the track surface to detect the movement of magnets. The circuits are constructed on a printed circuit board (PCB). which may need to be separate from a substrate of the wire windings of the coils, requiring additional mounting, increasing cost and complexity.

[0005] Coils made from coiling wires in a LSM are comparatively thick relative PCB components, preventing them from being stacked. This means that custom coil shapes are often used at intersections in the automation tracks, as coils for diverging paths must be placed side by side in the plane of the surface such that magnetic fields are not uniform for the different coil shapes. Exemplary prior art coil geometries are shown in FIG. 1, including wound coil bobbins of varying sizes and arrangements.

[0006] For example, as show n in FIG. 1, a linear arrangement of parallel oval coils allows the creation of a straight section of an LSM track, while adjacent oval coils arranged in a curved relationship allows a curved section of LSM track. Synchronous activation ofcoils creates a moving magnetic field that moves to / from adjacent coils along the row of coils. While this arrangement allows wound-coils to effectively propel a magnet in a linear direction or a curved direction, the fields generated by coils become harder to manage and less uniform when the track branches, such as in track section 2. Track section is a control board onto which two groups of coils are mounted and potted, a straight group of coils 4 and a curved group of coils 6. By synchronously activating these groups of coils, a magnet in the base of a vessel mover / carrier can be selectively propelled along the chosen path. However, as can be seen in straight coil group 4, the coils nearest the intersection of the coil groups are smaller, which can limit the force applied to the magnets on the track, often requiring a mechanically switchable guide to assist the diversion of the linear path. This is because the coils are quite thick relative to the width of the coils, so wound coils cannot be easily stacked. Stacking wound coils would move the top face of the bottom coil away from the track surface, causing a non-uniform diverging magnetic field at the track surface and reduce coupling efficiency.

[0007] Accordingly, there is a need for improved coil construction beyond the existing wound coils that mounted and potted to control boards along the track of an LSM mover system.SUMMARY

[0008] Described herein are systems and methods for tracking vessel movers in a liquid handler system and / or the liquid samples carried thereby using sparse sensor assemblies.

[0009] In an exemplary' embodiment a vessel transport system in a liquid handler system comprises a vessel mover configured to transport a sample vessel and having a magnetic base, a track comprising a poly-phase drive comprising n number of phases and configured to provide a plurality of selective magnetic fields to propel the magnetic base of the vessel mover along the track, wherein each phase is configured to provide current to one of a plurality of coils comprising n number of coils, and a processor. The processor is configured to control selective application of currents to the track to create the plurality of selective magnetic fields using n-1 of the plurality of coils, wherein one or more coils receiving current are one or more active coils and at least one coil not receiving current is an inactive coil, and receive back electromagnetic field (BEMF) measurements from the inactive coil and use the BEMF measurements to determine a vessel mover’s position and velocity.

[0010] In some embodiments, the processor is further configured to determine the active coils. In some embodiments, the track further comprises a plurality of multilayer printedcircuit boards (PCB) arranged along a transport path, wherein each PCB has a plurality of multi-layer conductive coils within layers of the PCB and includes a plurality of single-layer spirals electrically coupled with one another to form a multilayer coil. Determining the active coils can include determining a plurality of track coils proximate the vessel mover and determining a subset of proximate coils. The subset of proximate coils comprises coils that, if activated, would cause one or more magnetic fields to propel the magnetic base forward. Determining the active coils includes identifying one or more coils that correspond with the subset of the proximate coils. In some embodiments, determining the coils proximate each of the vessel movers includes sensing a magnetic field from the magnetic base of the vessel mover.

[0011] In some embodiments, determining the subset of proximate coils that, if activated, would cause the plurality' of selective magnetic fields to propel the magnetic base forward includes determining one or more coils of the subset of proximate coils that, if activated, would attract a front end of the vessel mover or would repel the back end of the mover. In some embodiments, the processor determines an amount of current of each of the active coils. The determined amount of current can comprise a maximum input current for each of the active coils. In some embodiments, determining the amount of current includes calculating the amount of current using a constrained optimization problem. An objective function of the constrained optimization problem can include minimizing a weighted sum of the squared determined amounts of current and a constraint of the constrained optimization problem comprises a required force to propel the magnetic base and limits on the current inputs to each active coil.

[0012] In some embodiments, the track further comprises a plurality' of Hall effect sensors and the processor is further configured to also use signals from the plurality of Hall effect sensors to determine a vessel mover’s position and velocity.

[0013] According to another embodiment, a computer-implemented method for moving a vessel mover along a track and sensing the vessel mover’s position and velocity', (where the vessel mover has a magnetic base and the track has a poly-phase drive comprising n number of phases and is configured to provide a plurality of selective magnetic fields to propel the magnetic base of the vessel mover along the track, wherein each phase is configured to provide current to one of a plurality' of coils comprising n number of coils) iteratively includes the following steps. The method includes controlling selective application of currents to the track to create the plurality of selective magnetic fields using n-1 the plurality of coils (wherein one or more coils receiving current are one or more active coils and at leastone coil not receiving current is an inactive coil), receiving BEMF measurements from the inactive coil, and determining one or more of the vessel mover’s position and velocity using the received BEMF measurements.

[0014] In some embodiments, the method includes determining the one or more active coils. In some embodiments, the track further comprises a plurality of multilayer printed circuit boards (PCB) arranged along a transport path, each PCB having a plurality of multilayer conductive coils within layers of the PCB. and each coil comprises a plurality of singlelayer spirals electrically coupled with one another to form a multilayer coil. In some embodiment the step of determining the one or more active coils comprises determining one or more coils proximate the vessel mover, determining a subset of proximate coils (wherein the subset of proximate coils comprise coils that, if activated, would cause one or more magnetic fields to propel the magnetic base forward), and determining the one or more active coils by determining the one or more coils that correspond with the subset of the proximate coils.

[0015] In some embodiments, the step of determining the one or more coils proximate each of the vessel movers comprises sensing, from the magnetic base of the vessel mover, a magnetic field. In some embodiments, the step of determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises determining one or more coils of the subset of proximate coils that, if activated, would attract a front end of the vessel mover. In some embodiments, the step of determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises determining one or more coils of the subset of proximate coils that, if activated, would repel a back end of the vessel mover.

[0016] In some embodiments, the method includes determining an amount of current of each of the one or more active coils. In some embodiments, the step of determining the amount of current of each of the active coils comprises calculating the determined amount of current using a constrained optimization problem, wherein an objective function of the constrained optimization problem comprises minimizing a weighted sum of the squared determined amounts of current and a constraint of the constrained optimization problem comprises a required force to propel the magnetic base. In some embodiments, no two active coils are adjacent.

[0017] According to another embodiment, a computer program product is configured to perform a processor for moving a vessel mover along a track and sensing or more of thevessel mover’s position and velocity, and the computer program product comprises a computer readable storage medium having program instructions embodied therewith. The program instructions are executable by a processor to cause the processor to control selective application of currents to the track to create one or more magnetic fields using n-1 of phases of a poly-phase drive, (wherein each phase of the poly-phase drive is configured to provide current to one of a plurality’ of coils comprising n number of coils and wherein one or more coils receiving cunent are one or more active coils and at least one coil not receiving current is an inactive coil), receive BEMF measurements from the inactive coil, and determine one or more of the vessel mover’s position and velocity' using the received BEMF measurements.FIGURES

[0018] The accompanying drayvings, yvhich are incorporated in and form a part of the specification, illustrate the embodiments of the invention and together with the written description serve to explain the principles, characteristics, and features of the invention. In the drawings:

[0019] FIG. 1 is a top vie v of prior art yvound coil tracks;

[0020] FIG. 2A is a top down view of an exemplary sample handling module, in accordance with at least one aspect of the present disclosure;

[0021] FIG. 2B is a perspective view of an exemplary sample handling module in accordance with at least one aspect of the present disclosure;

[0022] FIG. 3 is a diagrammatic view of an exemplary' integral, modular automation track system, in accordance with at least one aspect of the present disclosure;

[0023] FIG. 4 is a perspective vieyv of an exemplary’ automation track system, in accordance with at least one aspect of the present disclosure;

[0024] FIG. 5 is a perspective vieyv of an exemplary' automation track system, in accordance w ith at least one aspect of the present disclosure;

[0025] FIG. 6 is a cross sectional view of an exemplary automation track system, in accordance with at least one aspect of the present disclosure;

[0026] FIG. 7 is a top-down view of an exemplary' automation track system, in accordance with at least one aspect of the present disclosure;

[0027] FIG. 8 is a diagram of a track segment of a liquid handler system, in accordance with at least one aspect of the present disclosure;

[0028] FIG. 9 is a diagram of a vessel mover actuator, in accordance with at least one aspect of the present disclosure;

[0029] FIG. 10 is a diagram of a liquid handler system including a vessel tracking system, in accordance with at least one aspect of the present disclosure;

[0030] FIG. 11 is a top view of a PCB coil in accordance with at least one aspect of the present disclosure;

[0031] FIG 12 is a cross sectional view of a PCB coil in accordance with at least one aspect of the present disclosure;

[0032] FIG. 13 is a top view of a PCB coil track in accordance with at least one aspect of the present disclosure;

[0033] FIG. 14A is a top view of a PCB coil track intersection in accordance with at least one aspect of the present disclosure;

[0034] FIG 14B is a cross sectional view of a PCB coil intersection in accordance with at least one aspect of the present disclosure;

[0035] FIG 14C is a cross sectional view of a PCB coil intersection in accordance with at least one aspect of the present disclosure;

[0036] FIG. 14D is a top-down x-ray view of a PCB coil track intersection in accordance with at least one aspect of the present disclosure;

[0037] FIGs. 15A-C is a top-view of an exemplary vessel mover traversing a PCB coil track intersection in accordance with at least one aspect of the present disclosure;

[0038] FIG. 16 is a top view of a PCB coil track intersection in accordance with at least one aspect of the present disclosure;

[0039] FIG. 17A is a top view of a PCB having a coil track in accordance with at least one aspect of the present disclosure;

[0040] FIG. 17B is a top view of a PCB having a coil track intersection in accordance with at least one aspect of the present disclosure;

[0041] FIG. 18A is a flow chart of a method of phase activation to drive a vessel mover and sense BEMF, according to an embodiment of the disclosure;

[0042] FIG. 18B is a block diagram of a system for phase activation to drive a vessel mover and measure BEMF, according to an embodiment of the disclosure;

[0043] FIG. 19A-19F are diagrams of a vessel mover traveling across a track as coil arrays are activating and deactivating using method, according to an embodiment of the disclosure;

[0044] FIG. 20 is a block diagram of a system for phase activation to drive a vessel mover and measure BEMF, according to an embodiment of the disclosure;

[0045] FIGS. 21 A-21P are graphs of simulation results, according to embodiments of the disclosure; and

[0046] FIG. 22 illustrates an exemplary computing environment within which embodiments of the invention may be implemented.DESCRIPTION

[0047] This disclosure is not limited to the particular systems, devices and methods described, as these may vary'. The terminology' used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope.

[0048] As used herein, the terms “algorithm,” “system,” “module,” “engine,” or “architecture,” if used herein, are not intended to be limiting of any particular implementation for accomplishing and / or performing the actions, steps, processes, etc., attributable to and / or performed thereby. An algorithm, system, module, engine, and / or architecture may be, but is not limited to, software, hardware and / or firmware or any combination thereof that performs the specified functions including, but not limited to, any use of a general and / or specialized processor in combination with appropriate software loaded or stored in a machine-readable memory' and executed by the processor. Further, any name associated with a particular algorithm, system, module, and / or engine is, unless otherwise specified, for purposes of convenience of reference and not intended to be limiting to a specific implementation. Additionally, any functionality' attributed to an algorithm, system, module, engine, and / or architecture may be equally performed by multiple algorithms, systems, modules, engines, and / or architectures incorporated into and / or combined with the functionality of another algorithm, system, module, engine, and / or architecture of the same or different type, or distributed across one or more algorithms, systems, modules, engines, and / or architectures of various configurations.Automated Liquid Handler Systems

[0049] A liquid handler or liquid handling robot system that is designed to dispense and process any ty pe of liquid, including reagents and patient samples. Liquid handlers are particularly adapted to automate workflows in life science laboratories, such as clinical laboratories or research laboratones. Some liquid handlers, which can be referred to as “analyzers” or “analyzer systems” are additionally adapted to process and perform tests on samples using, for example, immunoassay and / or clinical chemistry' techniques.

[0050] Liquid handlers can include automation systems, either integrally or as modules coupled to the liquid handlers. Some liquid handler systems can include a number of modules or stations that are adapted to perform different tasks or tests. In these embodiments, the automation systems can include a transport system that is adapted to transport containers of samples and / or reagents between the various modules or stations. As noted above, transport systems can include friction-based movement systems, conveyor belts, and magnetically driven movement systems. Automation systems can further include sensor assemblies for detecting parameters associated with the containers or other aspects of the transport systems and control systems that are configured to control the movement of the containers accordingly.

[0051] In some embodiments, liquid handler systems can utilize a modular system including an automated clinical chemistry analyzer module and an automated immunoassay analyzer module, with sample loading capability to transport patient samples to and from analyzer module(s) where in vitro diagnostic assay analyses are performed. The system can be scalable in multiple configurations of the modules allowing customer yearly throughput needs ranging from low volume to very high volume / mega market segments (i.e., 500.000 to 5M or more tests per year).

[0052] In some embodiments, the automation system can be described as a process control manager (PCM) that manages the processing of samples. This includes providing input and output for samples into and out of the system, temporary storage of samples while awaiting processing, scheduling of samples for processing at various analyzers attached to the PCM, facilitation of the movement of samples throughout an automation track (including onto and off of the automation track), and. in some embodiments, maintenance of the automation systems. In various embodiments, a PCM can include a variety of different modules, including a sampler handler and a vessel mover.

[0053] The sample handler provides a means for the user to load and unload regular samples, STAT samples, and control / calibrator vials onto and off of the system. Within the sample handler, the robot subsystem is responsible for moving these tubes between other subsystems and modules, including the sample I / O (drawer trays), control storage, and the vessel mover.

[0054] The vessel mover subsystem handles this material distribution. Under normal conditions, a lab technician never operates the vessel mover track directly. The vessel mover manages carriers on an automation track that moves samples or reagents, each carrier having a dedicated type of holders. In some embodiments, liquid handler systems can includereagent carriers that are configured to accept a reagent cartridge and to transport the reagent cartridge, via the automation track, to a location accessible to the one or more analyzer modules. In some embodiments, a reagent carrier can be adapted to handle reagents from both an immunoassay module and clinical chemistry module.

[0055] FIG. 2A shows a top-dow n view of an exemplary7sample handler 10 that may be used for some embodiments. Within this figure, sample handler 10 is oriented so that the front (i.e., the face that the operator interacts with) is at the bottom of the page, while the back of the automation track is located at the top of the page. Sample handler 10 includes a tube characterization station 12 at the robot / track interface. Tube characterization station 12 characterizes tubes and carriers when tubes are placed on carriers on track 14. This allow s information to be ascertained about the identity of the tube placed in each carrier, and the physical condition of each tube (e.g., size of the tube, fluid level, whether there is a tube top cup, etc.) Adjacent to the tube characterization station 12 sits a control / calibrator storage region 14. This allow s long-term refrigerated storage of control and calibrator fluids near the track, allowing these fluids to be easily placed into carriers on the track for movement to relevant locations in the analyzer. The location of storage 16 also allows input / output drawers 18 to be placed in the front of sample handler 10. In this example, there are four adjacent drawers 18 that can be individually opened and pulled out.

[0056] A robot arm 20 can move in tw o dimensions to pick up any of the tubes in drawers 18 and move those tubes to and from storage 16 and carriers on track 14. Robot arm 20 can be positioned by moving a gantry' from the front to the back of a sample handler 10 while a carriage moves side to side along that gantry'. Opposable end effectors can then be moved vertically to reach down to pick up tubes, closing the end effectors when they are properly positioned to engage the tube.

[0057] To assist the robot arm 20 in successfully engaging each tube, a drawer vision system 22 is placed above the drawers at the opening to the drawers. This allows a series of images to be taken, looking down at the tubes in the trays, as the trays are moved past the drawer vision system. By strobing a series of cameras, multiple images can be captured in a buffer, where each tube appears in multiple images. These images can then be analyzed to determine the physical characteristics of each tube. For example, diameters and heights of each tube can be determined. Similarly, the capped or uncapped states of each sample can be quickly determined. Furthermore, the presence or absence of a tube top cup (a small plastic well that is placed on top of a tube to allow a tube to transport a much smaller volume with greater depth of the sample, to allow7aspiration to more easily take place) can be ascertained.Similarly, the characteristics of any cap can be ascertained by the images. This can include certain color markings on the cap to identify a given sample as a higher priority (STAT) sample.

[0058] The module manager PC can utilize this information to schedule samples to be moved from each tray in drawers 18 into carriers on track 14. The module manager PC can also instruct robot arm 20 how to interact with each tube, including identifying the proper height for the end effectors before engagement, and the proper force or distance to use when engaging the end effectors to accommodate multiple diameters of tubes.

[0059] FIG. 2B is a perspective view of a sample handler 10. In this example, track 14 is roughly parallel with the front face of drawers 18, while refrigerated storage 16 is a large physical object between drawers 18 and track 14. Meanwhile, robot arm 20 is moved on supports, well above the height of drawers 18 and refrigerated storage 16. In some embodiments, the sample handler 10 can include a tube characterization station 12 and a drawer vision system 22; however, these stations are omitted from the view in FIG. 2 in order to allow the internals of sample handler 10 to be better understood.

[0060] FIG. 3 illustrates the vessel mover components of the PCM that moves samples from an input region to analyzer modules, assists in handling those samples within the analyzer, and returns process samples to the output region of the sample handler. Multi module analyzer system 30 includes multiple interconnected modules. In this example, system 30 includes multiple sample handlers 10. By utilizing multiple sample handlers, more sample trays can be placed into the system, allowing a larger batch to be started at the beginning of the shift. Furthermore, this allows twice as many samples to be placed onto, and taken off of, the track. This means that, for larger systems with multiple analyzer modules that can operate in parallel, input / output throughput can match the analysis throughput of the parallel analyzers. For example, if an analyzer module can handle 500 samples per hour, and three analyzer modules are used, the input / output demand for feeding these modules may be up to 1500 samples per hour. In some embodiments, a single sample handler may not be able to handle this demand, necessitating adding multiple sample handlers to keep up with the input / output demand of the analyzer modules.

[0061] Furthermore, in some embodiments, one of the sample handlers can be set up to be used as an input, while the other sample handler can be set up as an output. By using a modular approach, a single sample handler 10 can be used but, for larger systems, two or more sample handlers can be used.

[0062] In an exemplary system 30, two analyzer modules are utilized. Analyzer module 32 is an immunoassay (IA) analyzer. Analyzer module 34 is a clinical chemistry (CC) analyzer. These two analyzer modules perform different assays, testing for different characteristics of patient samples.

[0063] Track 14 is a multi-branching track that forms the heart of the vessel mover system. As can be seen, track 14 comprises branches and lengths that are provided integral to sample handlers 10 and analyzer modules of 32 and 34. The functions of the individual branches will be explained with respect to FIGS. 5 and 6. In addition to the track segments provided by these modules, additional modules 38, 40, and 42 provide short, dedicated track sections that may be bolted to the track portions provided by the other modules. Track modules 36, 38, 40, and 42 provide powered track segments, without additional hardware related to sample handler modules or analyzer modules. Whereas modules 10, 32, and 34 may be full cabinets extending from a laboratory floor to the height of track 14, and above, track segment modules 36, 38, 40, and 42 may be bolt-on segments that extend from the cabinets of the other modules, without requiring floor-length support. Each of the modules in FIG. 3 can be bolted together in modular fashion, utilizing leveling hardware, such that each track segment between adjacent modules forms a virtually seamless track for carriers to traverse the vessel mover system.

[0064] In exemplary system 30, it can be seen that section 44 of the track of analyzer module 32 may need to be altered from the corresponding section of analyzer module 34. In some embodiments, the track segments of analyzer modules are in the same configuration as that shown in analyzer module 34 when they are shipped from the factory . This allows multiple analyzers to be placed in series, simply bolting their respective track segments together to form a long chain. In some embodiments, where there is an offset between the back track segment of the sample handler modules and the analyzer modules, as is illustrated in system 30, an S-shaped bend may be needed to allow carriers to move from the back track section of analyzer modules to the back track section of the sample handler modules. In this example, this S-shaped bend is provided by bolting on track section 42 and the altered track segment in area 44. Thus, it should be understood that the track segments within analyzer modules, while integral to those modules, can be extensively modified at the time of installation, allowing multiple configurations of the track segments within an analyzer module. However, it should be understood that these track segments are still very' much integral to those analyzer modules. In some embodiments, the back of analyzer modules 32and 34 are flush with the backs of sample handlers 10, eliminating the need for altering track segment 44 and section 42, entirely.

[0065] Track segments 38 and 40 are U-shaped track segments that provide returns between front track segments and back track segments, allowing traffic to move around the track 14 without traversing interior chord segments within sample handler or analyzer modules. This allows the track 14 to form an outer loop, with main traffic moving along the perimeter of the analyzer modules. Meanwhile, the internal track sections bypass the main loop, providing a direct path between two sides of each analyzer module (front to back), which serves as a route for local traffic. These chord segments can also be referred to as internal segments / track sections, bypass segments / track sections, or, in some cases, local track sections. These chord segments bypass the outer loop to provide access to a pipette. This allows small physical queues relevant to each sample handler or analyzer module to utilize those interior chord segments, without blocking the overall flow of track 14.

[0066] A specialized track segment module 36 facilitates sample return and branching within track 14 to allow the central computer system of the PCM to direct traffic in flexible ways. The outside track portions provide a way for samples to move from sample handler modules 10 to track segments of analyzer module 32, and vice versa. Meanwhile, the inner chord of track segment module 36 provides a branch whereby samples can move from analyzer 32 to analyzer 34 (in a counterclockwise manner), without moving into sample handler modules 10. This facilitates multiple tests on a single sample tube, allowing sample tubes to freely move between analyzer modules, regardless of how they are arranged on the right-hand side of system 30. This gives the PCM scheduling softw are flexibility in how samples order the tests within analyzer modules, without increasing traffic on the track segments relating to sample handling. Track segment 36 provides a boundary between sources and sinks (e.g., sample handler modules 10) and processors (e.g., analyzer modules 32 and 34) by providing a branching loop within section 36 (and section 42, in some embodiments). This loop allow s sample carriers to move betw een the sources, sinks, and processors, including allowing samples to loop without returning to the sources and sinks.

[0067] Not shown in FIG. 3 is the central computer that includes a system instrument manager software component. The instrument manager software consolidates information from lower-level modules, such as sample handler 10 and analyzer modules 32 and 34, to present this information to an operator. The instrument manager receives information from the other modules via a network within the system (e.g., an internal Ethernet network).Information may be requested and provided asynchronously betw een the modules and centralcomputer. The central computer can also work between the LIS and vessel mover systems to schedule samples and their movement within the system. The central computer can also work between the vessel mover systems and individual modules to handoff control of the samples and to initiate testing of samples once they arrive at a location.

[0068] Additional information regarding in vitro diagnostics sy stems can be found in U.S. Patent Application No. 16 / 319,306, published as U.S. Patent Application Pub. No. 2019 / 0277869A1, titled AUTOMATED CLINICAL ANALYZER SYSTEM AND METHOD, filed January 18, 2019, which is hereby incorporated by reference herein in its entirety7.PCB-Based Automation Track Configurations

[0069] Various liquid handlers can include a variety of different transport systems, including electro-magnetic drive systems, friction-based track systems, or conveyor belts. For example, some liquid handlers include a track having a plurality of synchronously controlled electro-magnetic coils. The vessel movers in this case typically consist of a permanent magnet array whose field interacts with that generated by the electro-magnet coil array on the track. In these analyzer systems, the automation track is configured to move the sample carriers via synchronously controlled electro-magnetic coils that propel the sample carriers along the analyzer system’s track sections. However, conventional electro-magnetically driven transport systems use metallic substrates for the automation track. Metallic substrates have several disadvantages, including cost and weight, as generally discussed above. Accordingly, embodiments of transport systems described herein include PCB-based substrates for the automation track. In these embodiments, each track segment can include one or more PCBs having coil arrays that are configured to electromagnetically actuate the vessel mover to transport the vessel mover therealong.

[0070] In some embodiments, track sections are divided up into a number of coil boards. Prior art coil boards include a linear array of coils that can be mounted to the PCB substrate of the track. In some embodiments, the coils are formed in the copper layers of the PCB itself. For straight sections of track, each coil board is straight, while, in comers or curves, coil boards include appropriately laid out coils to match the curve. In some embodiments coil boards are controlled by master boards and node controllers. In some embodiments, each master board can control up to eight different coil boards. Meanwhile, a node controller is centralized. A single node controller can control the entire vessel mover track. In some embodiments, multiple distributed node controllers can be used for expandability7. Forexample, in larger systems, where the track extends for several meters, multiple node controllers may be used, and control of carriers can be handed off as they traverse different regions of the track network. In some embodiments the components of the master boards can be integrated directly into the coil boards, allowing inclusion of control and drivers and magnetic coils on the same circuit board.

[0071] FIG. 4 shows a perspective view of track system 160. Track system 160 is configured to have a single sample handler unit and two analyzer modules. FIG. 5 shows track system 160 situated in a fully operational analyzer system 162 that includes a sample handler module 10 and two analyzer modules of 32 and 34. As can be seen, track system 160 is housed within the modules themselves, such that the track is not easily accessible to an operator. However, track 160 and analyzer system 162 utilize a modular design whereby track components reside within each module and each module can easily be linked together to join the track segments by placing adjacent modules in proximity7and linking them. Lids above track 160 can be removed during installation or service to facilitate linking of tracks. In some embodiments, track sections are expanded by placing modules adjacent to one another and bolting the track sections of each module together forming a single multi-branching track system, such as track 160. Signaling cables can be daisy-chained together for ease of expanding control.

[0072] FIG. 6 shows a cross-sectional view of an embodiment of track section 170. Track section 170 may be a track section used in track 160. In this embodiment, carriers ride between rails 172 on a track surface 174. In some embodiments, rails 172 are aluminum extrusions that also include vertical sides on the exterior of the track components underneath track surface 174. These aluminum extrusions can include brackets to easily bolt internal components to these side pieces to form a track unit. In the embodiments described herein, the track surface 174 is a PCB. In various embodiments, the PCB track surface 174 can include one or more coatings or other components. At the bottom of the side components of rails 172 resides a baseplate 176. Baseplate 176 can be mounted to the modules containing track section 170 and provide support for the track system.

[0073] Beneath track surface 174 reside a series of coils 180. The longitudinal direction of track section 170 is into the page; as you travel along the track section 170, you encounter additional coils 180. In prior art versions, coils 180 are wound-bobbin coils that are mounted to coil boards 182. They are laterally oblong to allow more coil density in the longitudinal direction of the track. In some embodiments, coil boards 182 are printed circuit boards (PCB) that include several coils 180 in the longitudinal direction. In some embodiments, coils 180are not wound coils, but are themselves printed in a multi-layer PCB as explained throughout, making coil boards 182 and coils 180 much thinner than they appear in FIG. 6. Furthermore, in some embodiments, coils 180 can be printed directly in the layers of coil boards 182, making boards 182 and coils 180 one monolithic entity, making the combination even thinner. Thus, FIG. 6 is merely illustrative and not intended to necessarily show scale.

[0074] An exemplary’ coil board is 250 mm in length, accommodating all the coils 180 needed for 250 mm of track. Thus, a typical track section will have several coil boards 182, including dozens of coil boards 182 to make up an entire track system. In some embodiments, coil boards 182 receive a control signal to indicate the trajectory’ to apply to a carrier traveling along that coil board and a power source of 24 VDC. In some embodiments the PCB coil board itself forms the track (riding) surface. Coil boards 182 include coils 180, motor drivers to drive those coils, and one or more sensors to detect the presence of carriers traversing the track surface above the coil board by detecting the magnets of the carrier. These sensors can include Hall Effect sensors to detect the presence and location of the carrier traveling along the coil board. Accordingly, there may be more sensors than coils, allowing fine resolution of the position of a carrier traversing track surface 174. Furthermore, an RFID receiver may be utilized to receive an RFID signal that identifies the carrier traveling along the track surface. In some embodiments, magnetic signatures unique to each carrier can be detected by the Hall Effect sensors to determine the identity of the carrier magnetically. For example, a carrier traversing an array of Hall Effect sensors can be characterized at manufacturing to identify a unique signature of that carrier based on rise times and signal artifacts that are detected by the Hall Effect or sensor array as magnets in the carrier travel over that array. In some embodiments, smaller magnets than the main drive magnets may be placed in the bottom portion of a carrier to intentionally create a unique signature for each earner at manufacturing. This magnetic signature can be correlated to an identity of each carrier in software for the vessel mover system. An exemplary linear synchronous motor drive system utilizing wound coils is described in U.S. Pat. No. 9,346,371. Embodiments described herein improve upon this exemplary’ design by utilizing coils created directly within a multi-layer PCB.

[0075] FIG. 7 shows a top view of an exemplary track system 160 with the individual track sections identified. There are generally four ty pes of track sections that make up the modular design of track system 160. Exemplary prior art versions of these track modules utilizing wound coils are shown in FIG. 1. which illustrate the coil topologies used in the prior art. Each of these track section types can also be created using PCB printed coils, asdescribed herein. Switching segments 184 are an example of branches in the track. The track surface for switching segments 184, in this example is generally T-shaped, with rounded inside edges. In some embodiments, the rails of switching segments 184 include one straight rail (top of the T), one radiused rail (one inside comer of the T), and one radiused rail that includes a switching mechanism (other inside comer of the T). This switching mechanism is a movable rail component that can be turned a predetermined number of degrees to act as a switch (e.g., 20-30 degrees, depending on geometry). On one side of the rail component, it acts as a straight rail. On the other side of the rail component, the rail presents itself as a radiused rail forming an outside comer of a turn. By switching a movable rail component, that movable rail component can either provide the outside of a turn, or a simple straightaway rail. Thus, the mobile component provides a binary switch whereby switching segment 184 presents itself as a turn or as a straightaway, depending on the control signal. This can be used to divert individual carriers based on the state of the switching segment. It should be noted that, while the track may be bidirectional, only one end of the T can be connected to the center portion of the T to form a turn. Thus, while switching segments 184 may have three ports, essentially, one port may be switched to either of the other two ports, but those two ports cannot be joined together.

[0076] It should be noted switching segments 184 are limited in this example to T-shaped intersections because they use a coil topology like that shown in track section 2 in FIG. 1, due to the use of wound coils. As explained below, 4-way perpendicular intersections are possible, such as shown in FIG. 14A, when PCB-embedded coils are used because such a design allows for coils to be stacked or interleaved. In some embodiments, 3-way nonperpendicular intersections are achieved using stacked or interleaved PCB-embedded coils.

[0077] A simpler type of track section is a straightaway, such as outside straightaway 186 or inside straightaway 188. The basic components of straightaways 186 and 188 are a track surface and rails, with a series of coil boards providing linear motive forces along the direction of that straightaway. Straightaways 186 and 188 are identified separately in FIG. 7 because inside straightaways 188 can be operated under the control of the local module, rather than a vessel mover controller that controls the entire track 160, in some embodiments. This allows each local module to independently operate track sections 188 to act as a local random-access queue. The vessel mover controller can hand off control to the local module after moving a carrier from a switching segment 184 to the local inside straightaway 188. Similarly, when a local module has completed aspirations on a sample residing on inside straightaway 188, that module may move the sample carrier into a switching segment 184and hand off control to the vessel mover controller. In some embodiments, inside track sections 188 still operate under the control of the vessel mover controller that controls the entire track system 160. To control a local queue on inside straightaway 188, the local module can communicate directly with the vessel mover controller to request movement of carriers within track section 188. This allows the local module to manifest control over carriers in its queue by using a request to acknowledge the communication system, allowing the vessel mover controller to have expertise in moving individual carriers and operating track system 160.

[0078] A fourth type of track segment is a curved track segment 190. Curv ed track segment 190 provides a 90° bend with a predetermined radius (or other angular bend). This radius is preferably the same as the radius used in turns when switching track segments 184 are switched into a curve. The radius is chosen to minimize the space impact of curves while, at the same time, allowing carriers to move quickly around curves without encountering drastic lateral forces. Thus, the space requirements and speed requirements of automation track 160 can determine the radius of curved segments 190.

[0079] Electrically, curved segments 190 are substantially the same as straightaways 186 and 188. Each of these segments includes a plurality of coils that are activated, in sequence, to provide a linear motor in conjunction with magnets in the bottoms of carriers. Each coil is activated to provide a push or pull force on drive magnets placed in the bottom of each carrier. The speed at which coils are activated in sequence determines the speed of the carrier on that section of track. Furthermore, carriers may be moved into a position and stopped at a predetermined location with high resolution by activating coils at that location.

[0080] FIG. 8 shows an illustrative embodiment of a track segment 201 of an automation track system 200, such as the track system 160 as shown in FIGS. 4-7. As generally described above, the automation track system 200 is configured to support one or more vessel movers 202 (also referred to as a “carrier” or “sample carrier”), which are configured to receive a vessel 204 therein. The track segment 201 can include a riding surface 206, which is the upper surface of the track segment 201 that supports the vessel mover 202 thereon and along which the vessel mover 202 is transported between the modules or components of the automation track system 200. In some embodiments, the riding surface 206 can include an active region 207 that the vessel mover 202 is intended to move along. As shown, the active region 207 is the area corresponding to coils embedded in or below surface 206. The active region 207 can generally correspond to the medial portion of the riding surface 206, and the relative width or the region 207 (as defined by the coils) is a design choice affected by theplacement of magnets in mover 202. If any liquid contaminants are present on the active region 207. they could negatively impact or otherwise impair the movement of the vessel movers 202, as noted above. In some embodiments, the track segment 201 could include a PCB substrate, as generally described throughout. Optionally, guide rails 211 can be used to help limit the lateral placement of mover 202 relative to the track and active region 207.

[0081] Further, as shown in FIG. 9, the track system 200 can include one or more coil arrays 208 associated with each track segment 201. The coil arrays 208 can be configured to generate a magnetic field that interacts with the magnet 203 positioned within the base of the vessel movers 202. The coil arrays 208 and the vessel mover magnet 203 can collectively define a linear electromechanical actuator. By synchronously controlling the coil arrays 208, the track system 200 can propel the vessel movers 202 (and, thus, the vessels 204 containing any samples or other liquids held thereby) across the track segments 201 to the desired module or other component of the liquid handler system.

[0082] Additional information regarding transport systems for liquid handlers can be found in U.S. Patent Application No. 16 / 319,306, which is incorporated by reference above.

[0083] As generally described above and shown in FIG. 10. liquid handler system 250 can include a one or more modules 252 that are configured to process liquid samples, a track system 200 interconnecting the various modules 252, vessel movers 202 that receive the liquid samples and transport the liquid samples between the various modules 252 along the track system 200, and a coil array 340 associated with the track system 200 that is configured to drive the vessel movers 202 therealong. The liquid handler system 250 can further include a tracking system 258 that is configured to monitor the locations of the vessel movers 202 along the track system 200 and control the movement and / or routing of the vessel movers 202 accordingly. The tracking system 258 can further include a control system 254 and a sensor assembly 256 (e.g., one or more Hall effect sensors) that is associated with the track system 200 and configured to detect the vessel movers 202 therealong. The control system 254 can be coupled with the coil array 340 and is configured to control the coil array 340 in order to control the movement and routing of the vessel movers 202 along the track system 200, which in turn allows the vessel movers 202 to transport the liquid samples between the modules 252 in particular sequences and with particular timings according to the types of liquid samples being processed by the liquid handler system 250. The control system 254 can include hardware, software, firmware, or any combination thereof that is able to execute the described functions. In the illustrated embodiment, the control system 254 includes a processor 260 coupled to a memory 262 storing instructions that, w hen executed by theprocessor 260, cause the control system 254 to execute the described processes, steps, and / or functions. Control system 254 includes a hybridized movement control architecture, which is a circuit and / or related control software that monitors activity of vessel movers, such as RFID signatures and Hall effect sensors, and controls the selective application of synchronous currents to relevant coils in the LSM track. This creates a magnetic field to propel the one or more magnetic vessel movers along the track. The application of these currents can be done in accordance with a software-defined desired motion profile for the vessel mover and can be adapted based on real-time feedback from Hall effect sensors (or other motion sensors, such as optical) in the track to move the vessel movers in accordance with a desired control scheme.PCB Printed Coils

[0084] Existing electromagnetic actuator topologies include a combination of conductive wire wound round a bobbin in curved shapes which are then augmented by mechanical diverter mechanisms comprising engagement arms and associated motors to guide vessel movers off linear paths. These solutions are cumbersome to manufacture and suffer part to part inefficiencies due to the coil winding process and ability to assemble and align separate motor segments.

[0085] Embodiments instead utilize PCB manufacturing techniques in conjunction with movable vessel movers / carriers with bodies containing permanent magnets. A coupled electromagnetic device is created that is only possible due to the specific physics achievable within a PCB fabrication combined with mover and load constraints required by the application. A particular arrangement of artwork used to retain copper within the layer stack is prescribed which creates an exact relationship of resistance, inductance and mutual capacitance, which by design creates a specific relationship between factors optimized for the particular motion characteristics required by laboratory automation entities.

[0086] Spirals are formed on many PCB lay ers which are interconnected by vias through the substrate layer stack to create a coil with electrical properties that balance the thermal dissipation of copper losses with nominal and peak thrust forces required by the system. These interconnections are in some cases through the entire substrate stack and in others only connecting specific layers. The arrangement of spirals including but not limited to the width of copper, the separation from adjacent current carry ing conductors, the exact shift of spirals between layers, the length of copper between end caps, the gap at the center of a spiral stack coand the gap between adj acent spirals, as well as other design artifacts are all interdependent and optimized as a multi-objective solution.

[0087] The arrangement of spirals on each layer within the PCB layer stack creates sets of coils that enable electromagnetic forces to be produced in different directional axes. With coordinated switching of the coil layers, a coupled magnetic mover can then be motivated in different axes of motion with respect to the physical PCB. Motion may be along, across or a combination of more than one axis of the PCB substrate. Moreover, higher level routing between paths of travel may be achieved by designated motions such as performing 90 degree turns at the end of linear travel, a four- way diversion onto a perpendicular lane of travel, or continuation of a linear path without any mechanical assistance devices.

[0088] Embodiments presented here rely on physical contact between the static portion of the motor and the movable entities. Unlike typical linear motor designs there are no constraints on the motion of the moving parts relative to the stationary parts. In some embodiments, there are no contact guides, mechanical devices or bearings employed other than the normal friction that results from entities resting on the stationary PCB substrate. The friction resulting from the normal contacts are managed by material choices to minimize the friction, whilst at the same time ensuring the life of the surfaces is sufficient for the intended system lifespan. Coating can be applied to the PCB substrate and also the entity base (magnet and / or entity structure) to perform in concert as a pair achieving a specific regime of slipstick friction that the automation control system uses for exact positioning of entities relative to the PCB substrate.

[0089] Furthermore, the manufacturing processes of PCB design yield extremely high- quality surfaces and tight geometric tolerances that enable a novel segment-to-segment alignment scheme to be achieved. Features and flexible material selections in the supporting structure align the separate PCB motor segments which ensure seamless transfer of entities from one segment to another. This can be an important capability of laboratory automation solutioning in which open tubes of patient samples are conveyed over hundreds of segments in larger laboratory solutions.

[0090] The designs of the electromagnetic system, mechanical system, thermal system and controller architecture described above are tightly coupled, each providing features and functionality to the other as part of the optimization that manifests the complete laboratory' automation solution.

[0091] By using a PCB arrangement rather than winding insulated copper wire mechanically, any specific profile of the individual traces making up a coil can be easilycreated in design software. Coils can have a thickness dictated by the specific PCB manufacturing process selected, which may allow foils of any reasonable thickness to be used for each layer. Trace widths are dictated by the computationally created photoresist masks that are used during the printing process. Thus, a total cross-section for each coil trace can be selected as part of the design process without complicating the manufacturing process. Similarly, the gaps between individual layers of spiral coil traces are dictated by the properties of the layers selected, including the thickness of core or prepreg layers and their dielectric properties. Within each layer, the gap between adjacent traces in a spiral can be selected in the printing mask. In contrast, traditional wound coils are limited to a single round profile of copper wire and the dielectric thickness for the wire that is wound around a bobbin.

[0092] Similarly, the exact shape of each coil spiral can be selected during the design process, resulting in a photoresist mask and resulting coil traces having the desired shape. Because a printing process is used, there is generally no substantial penalty incurred by choosing one shape or another during the manufacturing process. This means that the outer profile of the windings can appear more rectangular to maximize the amount of copper used in the coils and the uniformity of the field. Any other design considerations can also influence the exact shape of the PCB spiral layers. Furthermore, individual spiral layers can have slightly different profiles and individual traces within each spiral can have different shapes with, etc. This allows coil design to be optimized to field parameters. Finally, because the PCB manufacturing process is controlled by a precise masking and etching process, repeatability between the different PCB boards can be easily achieved with high quality results.

[0093] FIG. 11 is a top view of a PCB coil 310. The primary7component of PCB coil 310 is a stack of spiral traces 314 in a multi-layer PCB. Spiral traces 314 can be printed on multiple layers of the PCB during the PCB fabrication process to allow a greater number of turns of PCB coil 310. Spiral traces 314 can be printed in a clockwise or counterclockwise direction depending on the application. Each layer of spiral traces 314 can spiral inward or outward along a conductive path, which can differ between layers. Layers of spiral traces 314 can be interconnected to one another by vias 312 and 316. Vias include what will be referred to as intra-coil vias 316 that connect one end of a single layer of coil trace to one end of a coil trace in an adjacent layer, allowing one large stack of traces to form a single conductive coil. Vias also include what will be referred to as terminal vias that provide a conducting path to the top layer and bottom layer of a coil stack, allowing electrical connection to the terminals of stacked coil.

[0094] Multi-layer PCBs can be constructed using any applicable technique including bylaminating alternating insulating layers with etched layers of copper (e.g., etched by masking and activating a photoresist layer that then allows the selective masking of copper when the copper layer is chemically etched). Vias are drilled and filled with a conductor (copper) to provide electrical paths between the etched copper layers. In general, coil 320 is an elongated coil having a long axis 315 and a short axis 317. Adjacent coils are placed along a track such that an edge (right or left) of each coil intersected by the short axis is substantially parallel with an edge of each adjacent coil (such as shown in FIG. 14A). By arranging coils in this manner, within each PCB and by placing PCBs together, form continuous groups of coils creating one or more continuous paths for the magnetic vessel movers to move along. That is, the coils are placed adjacent to one another in a horizontal plane defined by the PCB track surface, such that their longer sides are adjacent.

[0095] FIG. 12 is a conceptual illustration of the cross section of PCB coil 310, without the specific details of the insulator materials. Coil 310 is created by laminating layers 318, which are made up of etched copper layers and an insulating dielectric material such as fiberglass and resin core or prepreg sheets that are laminated in the presence of heat and vacuum. Any number of layers 318 can be used, allowing any number of turns in printed coil to be created (the number of turns in each spiral times the number of layers of spirals gives the total turns for the printed coil 310). For example, a few hundred turns can be achieved by a dozen turns per spiral layer and twenty layers. The exact arrangement of traces within each spiral and how those traces are spaced relative to adjacent layers can be chosen to meet EMI or other specifications. In some embodiments, each conductive coil comprises at least twelve single-layer spirals, and each spiral comprises at least twelve turns.

[0096] In the single-coil example shown in FIG. 12, the races forming the spirals are shown in black, while the copper traces 320 that run from the spirals to vias 312 and 316 are illustrated separately7for clarity. While vias are illustrated as overlapping in the two- dimensional cross section, the vias do not actually overlap, instead being formed in separate holes in the PCB. Top surface 321 of the PCB provides a track surface for vessel movers. In some embodiments, a low friction surface, such as s high density polymer (HDPE. UHMWPE, or UHMW adhesive films), liquid photo imageable solder mask (such as LP-40), or PTFE, is applied to surface 321 after PCB manufacturing to facilitate smooth movement of vessel movers.

[0097] FIG. 13 shows a series 311 of parallel PCB printed coils 310. By printing these coils in parallel, they can be synchronously activated to create a moving magnetic field todrive a magnet in the base of a vessel carrier in either direction along direction 322. Depending on design requirements, any suitable number of coils can be printed on a single board and additional boards can be placed adjacent to one another to create a track of any length. In this example, the demarcation between separate PCB boards is not shown. In some embodiments, six coils are printed per PCB board.

[0098] The example shown in FIG. 13 is a simple straightaway where symmetrically oval coils are oriented in parallel. As explained below, different arrangements can be created for curves and junctions, such as adding a trapezoidal component to the shape of the oval coils and aligning adjacent coils to have parallel edges (such as shown in FIG. 16). The specific aspect ratio of the coils, width and length, center size, overall shape, and spacing between coils can be selected to create an LSM with desired physical properties.

[0099] FIG. 14A illustrates how an intersection that can be created using PCB printed coils. Unlike traditional bobbin-wound coils, PCB coils are substantially thinner for the same number of turns. This means that two coils can be stacked upon one another without moving the track surface substantially away from the edge surface of the coil. When a magnet is spaced away from the surface of a spiral coil, the magnetic field diverges, and the field is less uniform and strong due to fringing effects. Therefore, it is desirable to keep the surface of the track as near to the top edges of the horizontally -laying coils as possible. This is unachievable with traditional mechanical windings.

[0100] Here, coils are laid out in two intersecting directions, direction 322 as shown in FIG. 13 and perpendicular direction 324 as shown here. Note that directions 324 and 322 need not be perpendicular, in some embodiments, as any intersection layout can be achieved using stacked PCB coils. The arrangement shown in FIG. 14A can be logically grouped into two directional groups of coils. Coil group 328 is arranged horizontally along direction 322. Coil group 326 is arranged vertically in the page along direction 324. An intersecting group of coils 330 contains coils of both sets, stacked on one another or interleaved with one another. PCB coils 310A in group 326 can have substantially the same as or different characteristics from coils 310, depending on design requirements. To move a carrier from path 322 to path 324, a carrier can be moved to the intersection at coils 330 by selectively and synchronously activating coils in set 328 to move the magnet in the carrier to the intersection. Once the magnet has been moved to the intersecting group of coils 330, the coils within set 326 can be synchronously activated to move the magnet along path 324. Alternatively, if the carrier is not to turn at the intersection, the coils in group 328 will continue to synchronouslyactivate. The specific direction in which a carrier moves along path 322 or 324 is dictated by the order of synchronous activation of the coils.

[0101] Coil groups 326 and 328 form two paths of horizontally (in the plane of the PCB) adjacent coils. Each group provides a different direction of possible motion for vessel movers propelled by the selective creation of a magnetic field within each direction group of coils 326 and 328. By overlapping parts of each coil group 326 and 328 below the PCB track surface, an intersection is formed, allowing a vessel mover to selectively move between each directional group or continue on the same path as the directional group of coils that propelled the vessel mover to the intersection.

[0102] FIG. 14B shows a cross-section of the PCB layers used to create the stacked coils in section 330. It should be appreciated that only six layers are shown for illustration purposes, but in practice many more layers would likely be used depending on the application. In this example, solid black windings 314A illustrate the topmost coil, while white windings 314B illustrate the windings in the bottom coil. Each coil is created bystacking spirals that are electrically coupled through intra-coil vias 316, linked by copper traces 320. Terminal vias 312 provide terminal leads for a circuit to provide a current to each individual coil. It should also be appreciated that while FIG. 14B shows individual windings of the two stacked coils directly on top one another, the individual traces of the windings for each stacked coil go in different directions and only have this stacked arrangement at the intersection of the individual traces. That is. there will be portions of each stacked coil where the windings from the topmost coil are not directly atop the w indings of the bottom most coil, as can be seen in FIG. 14D.

[0103] In some embodiments, the stacked coils of windings 314A, 314B are laminated into a single monolithic PCB board having a number of layers that is at least twice the number of layers of each coil. In some embodiments, stacked coils can be created by creating two separate PCBs for each coil group and then stacking those PCBs. These stacked PCBs can be affixed to one another using any suitable fixation technique, such as epoxy or screw s.

[0104] When stacked coils are created using a single laminated PCB, it is also possible to interleave the windings of each coil such that the topmost surface of each coil is roughly adjacent to the surface of the PCB. Such an example is shown in FIG. 14C, where layers of windings 314A and windings 314B are printed on interleaved laminated layers of the PCB. This requires slightly longer vias to connect the non-adjacent layers to form a single coil.

[0105] FIG. 14D is an x-ray view showing an exemplary arrangement of stacked coils to illustrate the individual traces and show how they intersect in the adjacent PCB layers. Thearrangement of vias is merely conceptually illustrative. The specific arrangement of vias for stacked coils in a monolithic multi-layer PCB would be carefully selected to avoid interfering with individual traces of the stacked spirals.

[0106] FIG. 15A through 15C shows an exemplary progression of a carrier traversing the intersection first illustrated in FIG. 14A. A carrier 202 travels along the coil set 328 left to right. (In this example, carrier 202 is depicted as somewhat rectangular, but in some embodiments, carrier 202 can have a circular base, as shown in FIG. 8.) This is accomplished by synchronously activating coils 328 to create a moving magnetic field that guides the magnet(s) or conductors having a magnetic field (e.g., electromagnets or induced fields) in the base of carrier 202 from left to right.

[0107] Once the magnets in the base of carrier 202 reach the intersecting group of coils 330, the current through coils 328 can be reduced or stopped and currents in group 326 can be synchronously applied to create a moving magnetic field that goes down the page. Thus, in FIG. 15C, carrier 202 is moving down the page along coil group 326. Currents are no longer applied to coil group 328, and currents are applied synchronously to coil group 326 to create a localized moving magnetic field that moves down the page.

[0108] While a perpendicular intersection is illustrated in FIGs 14A through 15C, any angle can be used. For example, as shown in FIG. 16, the paths of intersection 350 do not need to be completely linear. Coils shown in FIG. 16 are shown conceptually, with the individual shapes of the coils generally having more rounded comers in practice. FIG. 16 shows a non-perpendicular intersection similarly to PCB 2 shown in FIG. 1. However, in prior art wound-coil boards, coils are too thick to be stacked with desired field characteristics, necessitating non-uniform shapes and sizes for the coils on forking paths, as shown in FIG. 1. Intersection 350, in contrast, allows any desired coil shape as the top coils are stacked with the bottom coils so they do not compete for space. Because they are stacked, there is no need to use smaller coils for one branch versus the other. This allows for a more uniform electric field to be used in the intersection without favoring one path or the other.

[0109] In exemplary intersection 350, a single path 352 (left) diverges into two branches, straight path 354 and right path 356. This allows path 352 to branch without requiring carriers to slow" down substantially at the intersection (acting more like a highway offramp than a perpendicular intersection. To accomplish this at least some of the coils of path 354 are at least partially stacked in the PCB with the coils in path 356. For example, coils 358 (which have an overall trapezoidal shape) of path 356 are printed in a stacked manner with coils 360 (which have an overall oval or rectangular shape) of path 354. Meanwhile, coil groups 362, re364, and 366 of path 352, 354, and 366, respectively, can be printed in PCBs without stacking with other coils. Thus, these coil groups may be created using PCBs with fewer layers to reduce cost. Coils 360 and 358 can be created in a stacked manner using any of the techniques discussed herein, such as interleaved, separate contiguous layers in a single PBC, or as separate multi-layer PCBs that are affixed atop one another after each PCB is manufactured.

[0110] It should be appreciated that the synchronous activation of coils can be selected according to a predetermined motion profile that sets maximum acceleration and / or maximum velocity constraints to limit vessel spilling. That is, the exact location of the magnetic field created by the selection and activation of a coils can move according to a motion profile that accounts for acceleration and maximum velocity for the application. For example, the motion profile can slowly accelerate a carrier to avoid spillage, moving the carrier faster as it continues to accelerate. Similarly, as a carrier approaches an intersection, such as the perpendicular intersection shown for 330, the carrier can slow down by applying a decelerating motion profile to your magnetic field, activating adjacent coils in a decelerating manner. Motion profiles are typically achieved by sending controller signals to driver amplifiers under softw are control. Software modules monitor the motion of each carrier and control the application of synchronous motor signals to the coils to achieve a desired trajectory.

[0111] As explained, coil tracks can have a series of adjacent PCBs each having multiple coils. These PCBs can be linked together to form a linear track of any dimension. This is similar to how wound coils were arranged into coil boards in a FIG. 1. Fig 17A shows an illustration of a six-coil PCB track section 370. Track section 370 comprises six PCB printed coils 310 arranged adjacent to one another to form a short linear track path. These coils can have a different overall shape (e.g. trapezoidal) to allow- other track geometries. Generally, coils are arranged adjacent to one another such that adjacent edges are substantially parallel. In the example shown in FIG. 16, coil group 366 includes trapezoidal and rectangular coils, but their adjacent edges face one another in such a way that a smooth curve is created. This substantially parallel relationship of adjacent edges can include perfectly parallel edges or slight wedges that match the trapezoidal profile of the adjacent coils in accordance with the curve.

[0112] Sensing of the entity locations with respect to a PCB substrate described is achieved by Hall sensors in specific locations on the same or adjacent PCB substrate / assemblies. Some embodiments do not use the traditional linear region of Hallsensor response. Instead, a set of numerical receipts are employed that makes use of one or more axis responses from a Hall sensor, from one or more Hall sensors to construct a position relationship between the entity and sensors. A sparse arrangement of sensors is achieved by using all the dynamic range from each sensor along with specific placement in ratio to coil locations. The specific position of Hall sensors is designed based on the information required, capabilities of the sensor wi th respect to the distance from the entity’ magnets and the function required at the location of sensors (for example a linear conveyance or directional change).

[0113] Hall effect sensors 372 can be included in the PCB 370, such as by soldering surface mount devices to pads on the PCB. By regularly placing Hall effect sensors along a track, the specific location of an individual carrier and its motion can be recorded and observed. Similarly, Hall effect sensors can provide real-time feedback about the overall health of the coils that they are adjacent to. These sensors can observe the magnetic field in its vicinity. This magnetic field will change as coils are activated and as the magnets in vessel carriers move on the surface above the hall effect sensor. Various computational approaches to utilizing Hall effect sensor data can be used to improve the handling and control of vessel carriers. One example of utilizing Hall effect sensor information is discussed in US patent application. 63 / 373,357, which is incorporated herein by its entirety'.

[0114] In addition to Hall effect sensors, other electrical components to assist the control and operation of the LSM track can also be incorporated into PCB 370. In some embodiments, motor controller circuits 374 can be placed on board 332. These can include FPGA or processors that control amplifiers mounted to PCB that provide a precise current to each individual PCB coil 310. This allows the coils to be activated synchronously according to a motion profile. In some embodiments, the motor control and drivers are mounted on a separate PCB, electrically coupled to coils 310.

[0115] FIG. 17B shows a PCB 380 that includes an intersection of tw o coil paths that includes a group of coils like group 330 in FIG. 14A. like coil group 330, PCB 380 includes stacked coils, 310 and 310A which are oriented with adjacent coils to provide motion horizontally and vertically in the page, respectively. These coils can be stacked separately or interleaved, as explained above. Hall effect sensors 382 can be mounted to the PCB inside individual coil loops to allow for monitoring of the motion of the magnets in the vessel carrier and to observe the health of coils by monitoring changes in magnetic field.

[0116] In some embodiments, motor control components 384 can be mounted on the underside of the PCB. This can present EMI challenges, so in some embodiments, motor control components 384 are mounted on a separate board for intersection PCB boards, likePCB 380. The Hall effect sensors are generally also mounted to the underside of PCBs so as to not interfere with the track surface.

[0117] Unlike other PCB coils the specific requirements of laboratory automation solutions results in very small payloads compared to existing solutions. For example, in a laboratory transport system there can be a maximum mover mass of 50g, with maximum payload of 20g moving at 0.5m / s. The reduction of scale is what enables the PCB solution to be realized and optimized as outlined in this disclosure. These low force requirements of entities with respect to one another means the existing Halbach magnet array can be simplified into an omnidirectional dipole magnet. This means the directionality of the existing design is removed further simplifying the design space and costs required for the application. Note that the methods described throughout are also applicable to other linear motor designs such as LSMs using wound coils and are not confined to PCB-based coil arrays alone.

[0118] As described above, the position of a vessel mover 202 can be determined using sensors. In other embodiments, in addition to or in the alternate, sensor-less feedback can be used to determine a vessel mover 202’s position, or even its velocity. “Sensor-less” feedback of a vessel mover’s position and velocity can be desirable for several reasons. For example, users can have more confidence in the results of a sensor-based approach when such its results are consistent with the results of a sensor-less approach. For another example, a sensor-less approach can provide system redundancy; if a system’s sensors fail unexpectedly, the vessel mover’s position and / or velocity can still be determined using the sensor-less method. For yet another example, a sensor-less approach can reduce or eliminate the number of system sensors, which will in turn reduce the cost and complexity of the system.

[0119] For electro-magnetic actuators, sensor-less feedback can be achieved by measuring back-EMF (“BEMF”) and modeling a vessel mover’s position and / or velocity’ therefrom. The BEMF is proportional to the rate (i.e., velocity) at which a magnet moves past and inductor. Hence, measurement of the BEMF provides a means of indirectly sensing the velocity of the object, such as a vessel mover that comprises a magnet. In the case of a 3- phase permanent magnet synchronous motor (“PMSM ”), the ratio of the BEMF components in the 2-phase stator frame (alpha-beta phases) equals that tangent of the position (in angular units / phase) of the rotor relative to the stator-fixed alpha-beta frame. In this case, measuring the BEMF components would yield an indirect measurement of the rotor position in angular (i.e., phase) units.

[0120] Conventional methods for sensor-less feedback of a vessel mover’s 202 position and / or velocity have significant disadvantages. Consider a model based BEMF observer. Because this method is predicated on well-characterized parameters for the vessel mover and robust measurement of coil currents, it suffers from reduced accuracy when the conditions are not satisfied. Another conventional solution involves deactivating one or more phases of a poly-phase drive scheme and directly measuring the BEMF on the deactivated coil. While this method can generally be more accurate than the model based BEMF observer method, it requires interruptions to the drive sequence that can result in degradation of motion quality of the vessel mover and loss of control authority. The latter can become important in the presence of high-bandwidth disturbances such as what would be commonly experienced on a track-based lab automation system having contact interface between the vessel mover and the riding surface. Yet another conventional solution is use of a 2-phase trapezoidal drive, as in a brushless direct current (“BLDC”) motor architecture, wherein only two out of three phases are active at any given time for motor operation. This allows for BEMF sensing on the inactive phase at all times. However, the trapezoidal drive design requires a suitable motor design and suffers from lower efficiency, higher current requirements, and a less smooth motion dynamics.

[0121] In another embodiment, one coil of a 3-phase PMSM drive-type linear motor is used for BEMF sensing and the ‘active’ coils are driven in a quadrature (stepper-like) drive scheme. Depending on the application, these actuators may suffer from less-smooth motion dynamics and poorer resolution of motion control compared to PMLSM motors. The efficiency of these motors can be lowered due to repurposing a PMSM type design for a stepper-drive operation that makes the actuator design less optimal for this drive scheme.

[0122] The method described herein involves selectively activating and deactivating coils in coil arrays to drive vessel mover motion while simultaneously having one coil inactive for BEMF measurement. This method can be simple and easy to develop and implement on a poly-phase system. It allows for uninterrupted driving of the coil without requiring pulsewidth modulation-blanking type schemes that interrupt portions of the pulse-width modulation (“PWM”) cycle for BEMF sensing. Similarly, the methods disclosed herein also address the disadvantages of schemes only involving measurement of BEMF during PWM zero-crossings, which can result in a very short duration over which the BEMF measurement is made. (Thus, those designs can be very sensitive to measurement noise and require an accurate determination of the zero-crossings). As a result, the results can be less noisy signals and, in turn, provide more accurate estimates of the vessel mover position and / or velocity.Further, by freeing the drive scheme of the 3-phase synchronous I sinusoidal drive constraint, the active coils can be commanded at max current inputs on each thus significantly increasing the maximum force capability of the linear motor. Accordingly, in some embodiments, the method can also include optimally allocating coil current references across the active coils.

[0123] FIG. 18A is a flow chart of a method of phase activation to drive a vessel mover and sense BEMF, according to an embodiment of the disclosure. At step 1801, method 1800 can include sensing the magnetic field from the vessel mover 202’s magnetic base. For example, by performing a peak-detection of the Hall sensor signals across the Hall sensor array, the coil that the puck is most proximate to can be determined. Based on the vessel mover 202’ s sensed magnetic field, at step 1802, the method 1800 can include determining which coils are proximate the vessel mover 202. At step 1802, a circuit or processor determines the set of three coils most proximate to the magnetic puck by performing, for example, a windowed peak-detection on the BEMF voltage waveforms measured across the coil array. At step 1803, based on the identified coils most proximate to the puck and the relative BEMF magnitudes, the processor or circuit determines the three phases of the identified triad of coils that need to be activated to propel the puck (coil corresponding to peak BEMF value along with coil on either side) based on a conventional 3-phase PMSM scheme. At step 1804, the required actuation force reference is computed by the motion controller. Based on prior information about the position of the puck, using the optimal 2- phase control allocation scheme described below, the one or two coils that would be activated to generate the required thrust are identified along with the optimal reference current commands to each of these coils. At step 1805, the required currents are then applied by the current controller to the one or two ‘active’ coils. Note that in some cases driving just one coil at any instant of time may be optimal. In these situations, the state estimate can be based on BEMF measurements on the two 'inactive’ coils. One ‘inactive’ and two 'active’ coils, however, would be the most common scenario. At step 1806, the inactive phase(s) (coil(s) not activated) is then used to sense BEMF. At step 1807, using the measured BEMF, the position and velocity of the puck can be estimated using for example, a model-based Observer or State Estimator that employs a model of the BEMF as a function of puck position relative to the BEMF-measuring coil. The feedback of the estimated state (position and velocity) is then used by the Motion Controller to issue the actuation force reference commands at the next sampled time instant. Steps 1801-1807 are repeated.

[0124] FIG. 18B is a block diagram of the software or circuit used to carry out method 1800. System 1820 receives two primary inputs from memory and produces two primaryoutputs to the controller (and can be used by other functional blocks, such as state estimation). System 1820 receives a control reference 1822, which passes through low-pass filter 1826 to produce a filtered reference signal. Reference 1822is the actuation force setpoint, (i.e. , the required actuation force determined and commanded by the upper-level motion controller). In the case of a conventional nested PID-loop architecture, the velocitycontrol (inner loop) and (outer) position control loop would constitute the upper-level motion control. System 1820 receives an estimated state 1824 from memory, which can include the most recent model of position and velocity of the magnet relative to coils in the array. This is handled by a coil activation logic block 1828, which determines the 3-phase coil set proximate the vessel mover, the active coil pair (or single coil in some cases) to be used, and an actuator thrust coefficients (mapped as a function of puck position relative to each coil), K The outputs of activation logic 1828 and LPF 1826 are used by cunent reference generator 1830 to optimally allocate control reference currents to the active coil pair, as explained with reference to the equations below. Coil activation logic block 1828 determines the triad of coils proximate to the puck, and the 2-phase optimal control allocation is performed by current reference generator block 1830.

[0125] Eq. 1)

[0126] Where KfXis the coil-to-puck position-dependent actuator thrust force coefficients. Further, a constraint is imposed so that current commanded to the two (active) coils should each be less than a max current Imax. Kfx and I are both vectors. Minimization of a weighted sum of the coil currents is used for example, as the optimization objective. The objective function for this constrained optimization problem e (p( ), which is therefore defined as:

[0128] We can assume equal weighting of two coil currents. H is a positive semi-definite matrix that can be defined as:

[0130] In some embodiments, an alternate model that includes a model of frictional drag relating to parasitic z-force generated by the coil can be used:

[0132] / i is a nominal estimate of the coefficient of friction between the moving magnet on the riding surface and KfZx) is the actuator vertical force (parasitic) constant. K fz(x) andKfX(x) are based on models of the actuators and can be guided by empirical calibration data measurements or by manufacturing specs. In an exemplary case, the constrained optimization solution yield the following expression for the two independently driven coil currents:101331

[0134] xi and X2 are the coil centers of the two active phases. Depending on the model used, Kf could be that used in Eq. 1 or Eq. 4.

[0135] The output of current reference generator 1830 includes a current reference that is considered by current control block 1834 along with the present current in the coils, the index of coils to be activated and their thrust constants (from activation logic 1828), and the estimated velocity and position from estimated state 1824. In addition, the coil across which BEMF would be sensed is identified. Current control 1834 enables tracking of the current setpoints (reference currents) commanded for each of the active coils by the current reference generator 1830. Current control 1834 in the general case could be comprised of a 2-dof control for each of the active coils. The two- DOF control includes BEMF feed-forward based on the measured BEMF, along with feedback control based on measured coil current control block 1834 generates output-saturated reference voltages (1836) and the index (1838) of the coils to receive the voltages. In some embodiments, current control 1834 utilizes a linear quadratic regulator (“LQR”) formulation that can be used to frame the control design problem as an optimal control problem. In some embodiments, the feedback portion of the current control 1834 utilizes a conventional proportional integral derivative (“PID”) architecture. In other embodiments, the current feedback control would be a Robust Control scheme based on the H-infinity method, or sliding-mode control scheme, or a Disturbance Observer-based Control (DOB) scheme, or a ADRC (Active Disturbance Rejection Control) scheme.

[0136] As part of the coil index identification, at least one of the coils proximate the vessel mover 202 should not be identified as an active coil, but as a BEMF sensor. In other words, at least one of the coils proximate the vessel mover 202 should be identified as the “inactive coil.’' This inactive coil can be used to measure BEMF, as described with respect to step 1806. In a typical 3-phase PMSM type coil architecture, all three coils are energized for generating thrust. In the described embodiments, the control scheme activates only at most two active phases at any given point in time. The control circuits / software identifies the three physical coils that need to be energized at any instant (these three coils would formphases A, B, C) out of which only two phases at most will be energized for generating thrust, the other phase will be used to measure BEMF.

[0137] In the case of consideration of more complex constraints and hence more complex optimization, the optimal control allocation problem can be solved numerically using any of a wide range of numerical optimization schemes such as Line Search, Trust-region methods, gradient descent, conjugate gradient method, etc.

[0138] The optimal control allocation can, for example, include in addition to the total actuation effort, control variation (rate of change of coil currents) as an additional variable to be minimized. This can be set up as a mixed-objective constrained optimization problem. Alternatively, the control variation can be limited, and the control variations bounds can be included as additional constraints along with limits on coil currents in the optimal control allocation formulation.

[0139] While a particular constrained optimization formulation is provided above, other forms of the constrained optimization formulation could include regularization to limit one of the two phases being overburdened with a significantly large proportion of the driving output and the minimization can be in the [infinity norm or more generally in the 1-p ( pth)norm instead of the 12 (energy) norm used in the original scheme.

[0140] It is to be noted that in some cases only one coil may be activated. In such instances one or both of the two inactive coils could be used for BEMF sensing.

[0141] FIG. 19A-19F are diagrams of a vessel mover 202 (and more specifically a magnet(s) therein) traveling across a track as coils are activating and deactivating using method 1800, according to an embodiment of the disclosure. Referring to FIG. 19A, coils 208a. 208b, 208c are proximate the vessel mover 202. Coils 208a and 208c are active. When activated, coil 208c creates a magnetic field to attract the front end of the vessel mover 202, and coil 208a creates a magnetic field to repel the back end of the vessel mover 202. As a result of the interaction between these two magnetic fields and the vessel mover 202, the vessel mover 202 is propelled forward (towards the right in this picture). Coil 208b is not needed to drive the vessel mover 202 forward so it is deactivated and used to measure BEMF. As the vessel mover 202 moves forward along the track, as illustrated in FIGS. 19B-19F, the coils proximate to the vessel mover 202 change, and the coils that, if activated, would drive the vessel mover 202 forward also change. The specific coils in the triad of coils making the ABC phases also change as the magnet traverses the coil array, as shown. Note that at most, only two coils within the triad are active at a given time. Thus, the three-phase arrangement isdriven more like a 2-phase drive as one of the phases is used for sensing at any given moment. For example, referring to FIG. 19F, coils 208b, 208c, and 208d are proximate to the vessel mover 202; coils 208b and 208d are active, and coil 208c is inactive and used for BEMF measurements. It is to be noted that whereas Fig 19 depicts an optimal 2-phase drive scheme for an actuator built as a 3-phase drive (for example, 3-phase PMLSM) with independent coil activation feature, the scheme can be extended to higher-order polyphase systems (e.g., 5-phase) as well.

[0142] FIG. 20 is a diagram of a system for phase activation to drive a vessel mover 202 and measure BEMF, according to an embodiment of the disclosure. Each of the blocks illustrated in FIG. 20 can be one or more computing devices or components (e.g., software or hardware engine or module) to perform certain tasks, as described herein. In some embodiments, one or more components of the control system 400 can be used to implement the method 1800. Control system 400 includes two high-level modules: a motion control module 410, which models the state of the motor (including a velocity' and position estimate of the magnet) and determines force requirements to move the vessel mover (magnet array) in a desired manner; and an actuation subsystem 430, which handles the low-level control of coils including determining the currents to be applied to individual coils, applying the currents, and sensing the BEMF signal from the coil(s) assigned to detect the BEMF. In some embodiments, the motion control module 410 can include a LQG (linear quadratic Gaussian (Feedback control module 412 and a Friction Compensator 420. In this embodiment, motion control 410 is a 2-DOF controller. This comprises a friction compensator (feedforward control part) and a feedback control based on the LQG. LQG comprises a linear quadratic regulator (LQR, control part) and a linear quadratic estimator to estimate the state (position and velocity) that is provided to the various components of the controller (e.g., LQR and friction compensator). LQG control module 412 receives BEMF sensor information (and any other position sensor information depending on what is available in a given embodiment, such as optical or Hall sensor information, if available) and maintains a state estimate of the position and its derivatives of the drive magnet array using suitable control principles known in the art or discussed herein. In some embodiments, a state estimator or observer in LQG control module 412 estimates the position and velocity of the puck based on prior estimate of the puck state and the measured BEMF signal (passed back from actuation subsystem 430). LQG control module 412 provides state estimate information to friction compensator 420 and actuation subsystem 430. In some embodiments, the friction compensator 420 can be a disturbance observer-based friction compensator. Using state information from the estimatorof the LQG control module 412 and providing friction estimate information thereto, friction compensator 420 determines an actuation force reference to be used by actuation subsystem 430 to compensate for friction. This combined with the actuation force reference generated by the feedback component (LQG control) is sent as the commanded actuation force reference to the actuation subsystem 430.

[0143] In some embodiments, motion control module 410 includes a two degrees of freedom C‘2-DOF”) control scheme that includes an LQG-based feedback control 410 along with friction / low-bandwidth disturbance compensation / friction compensator 420 using a disturbance observer. 2-DOF control is used for improved performance. Feedforward to compensate for known disturbances and forces is used in conjunction with feedback to compensate for input, environmental, and model uncertainties, resulting in significantly improved performance. Motion control module 410 determines the required control force input. This reference force input is then fed to actuation subsystem 430. In some embodiments, the higher-level motion controller can be one of many possibilities, including PID control with nested position and velocity loops, disturbance observer-based control, robust control methods, model reference adaptive control, and other state-space control methods.

[0144] Actuation subsystem 430 can include a coil activation logic module 431 that determines the set of coils (for example, triad coils for a 3-phase PMLSM architecture), an optimal coil current reference generator module 432, and a current control and drive module 433. In yet other embodiments, the Actuation Subsystem 430 can further include a Filter 434. In some embodiments, filter 432 can be a low-pass filter that filters out higher-frequency content from the actuation force reference input from friction compensator 420. The estimated position (and velocity, in some embodiments) of the puck is passed from LQG control module 412 to coil activation logic module 431 which determines the triad of coils that are most proximate to the puck.

[0145] Actuation subsystem 430 has three main functions: (a) to determine the pair of coils to be activated at any given time, which can be performed by the coil activation logic module 431, (b) to determine the optimal allocation of control current to the active phases, which can be performed by the optimal coil -current reference generator module 432, (c) to perform closed-loop current control on the two phases that are being driven (as well as measure BEMF across the inactive phase), which can be performed by the current control and drive module 433. The current control module can further provide 2-DOF current control, BEMF feedforward, feedback control, and output-saturated reference voltage. Optimal coil-current reference generator module 432 receives the indexes of the coils to be activated from coil activation logic module 431 and the filtered activation force reference from the motion controller 410 to determine the currents to apply to individual coils. Cunent control and drive module 433 uses this information, along with an identification of the roles of individual coils from coil activation logic module 431, to send currents to individual coils and to receive the BEMF signal from the identified quiescent coil. This measured / sensed BEMF signal is then provided to LQG control module 412.

[0146] There are several advantages of using the systems and methods described herein for phase activation to drive a vessel mover and measure back-EMF: it is robust, it is relatively easy to implement, it enables smoother vessel mover motion and less noise, the maximum force capacity of the actuator can be substantially increased, and it obviates the need for coil activation on an adjacent segment during vessel mover transition between segments (unlike a conventional 3-phase PMLSM drive implementation) . This method is more robust than (model-based) BEMF observ er-based schemes that work well only with high-fidelity phase current measurements and a good knowledge of the model parameters. It is also relatively easy to implement compared to methods involving PWM modulation / blanking, BEMF measurements during PWM zero-crossing, or observer-based BEMF estimation.

[0147] The method can enable smoother vessel mover motion and less noise due to the fact it does not use a blanking scheme. By enabling an uninterrupted actuation (PWM drive) without having to blank for BEMF detection this scheme eschews the pitfalls of using PWM blanking-based schemes for BEMF sensing. This in turn, improves control bandwidth and disturbance-rejection capability', thereby affording smoother vessel mover motion. This is important for mitigation of high-bandwidth disturbances such as those experienced on a lab automation track system, such as sample fluid spills and track contamination due to sloshing and splashing of the samples in the tubes in response to the vessel mover dynamics or other track surface contamination and other imperfections. Further, this method enables reduced PWM ripple / noise effects that would come with PWM modulation / blanking-based schemes.

[0148] The method is more robust relative to alternatives such as making BEMF measurements during PWM zero-crossing where the technique is highly timing-sensitive to within sub-microseconds. The method is also more robust relative to BEMF Observ er-based schemes where inaccuracies in state estimates can ensue from inaccurate representations of the system in the observer model.

[0149] Further, the maximum force capacity of the actuator can be substantially increased by use of this method. The method described herein frees the drive scheme of the 3-phase synchronous / sinusoidal drive constraint, which inherently constrains the peak force outputs. In the methods disclosed herein, the active coils can be commanded at max current inputs on the activate coils, which significantly increases the maximum force capability of the linear motor. This can be useful for high-bandwidth disturbance compensation. Examples of high- bandwidth disturbances include fluid spills and stick-slip mechanisms caused by changes to the riding surface.

[0150] Moreover, and importantly, use of this method obviates the need for coil activation on an adjacent segment during vessel mover transition between segments. In some embodiments, the actuator is a 3-phase PMSM linear motor. As described in this disclosure, the track can be made of individual segments joined together. At the segment transitions one or more of the three drive phases can be on the adjacent coil (track) segment. In the normal course the phases split across the segment transition need to be driven in a certain phased fashion specific to the PMSM operation in order to move the vessel mover. However, the proposed 2-phase optimal control-allocation scheme allows actuation using only two of the three PMSM drive phases. Therefore, the third coil (phase) lying on the adjacent track segment is not required to be activated. This eschews the need for the adjacent track segment having to sense the position of the puck in advance of its transition over to that segment, or a centralized controller having to coordinate position information between segment controller to coordinate coil activation across segment transitions.

[0151] A simulation was performed to simulate the results of using the method described herein using a LQG + DOB (Disturbance Observer Based Control) friction compensation control with optimal 2-phase drive. 2-DOF control was used for improved performance in terms of compensating high-bandwidth disturbance effects on the motion of the puck. Feedforward to compensate for known disturbances and forces in conjunction with feedback to compensate for input, environmental, and model uncertainties can significantly improve performance. For the vessel mover motion control as used on the track system described herein, frictional forces assume greater significance relative to typical motion control systems since they constitute a significant (up to 40-50%) of the total force requirement. In the simulation, the following was examined: a ‘delayed’ - feedforward compensation of friction in the form of a model-free disturbance-observer (low-order) whose estimate of frictional disturbance is then used to ‘cancel’ the effect of friction.The following inputs and assumptions were used in the model: 225 mm move along a straight segment of track commanded; current limit of 250 mA (Continuous) per phase imposed; voltage output saturation of 36 V imposed; external pulsed disturbance applied; friction modeled according Stribeck model actuator force constant= 0.9 x Kf(Kfderated by 10% in actual plant); Kfx= 12 mm (control model), 11.5 mm in actual plant model (K& offset is the position of magnet center relative to coil axis of symmetry at which Kfx is max); and mutual inductance of 0.1* self-inductance applied to actual plant. No mutual inductance coupling assumed in control model.

[0152] The following describes the control scheme and model used in the simulation. For the purpose of this simulation a simple current-control scheme is employed. PI control along with Back-EMF feedforward was used for each of the two phases. For simplicity, the current control is formulated assuming that the current dynamics of the two phases are fully decoupled. Note that the coupled dynamics (mutual inductance coupling) based on a Singular-perturbation formulation can be introduced. The simulated model included an electrical plant and a mechanical plant. Regarding the electrical plant, a simplified model of output feedback used; the sensor model is not explicitly modeled; instead position measurement noise (based on measured position error statistics) is added to actual carrier / magnet position to mimic estimated position, to be used as the position feedback signal. Mutual inductance coupling between the two phases was modeled. The actual force generated by the active coils derated with respect to what is assumed in the current control formulation: Kfamplitude derated and offset error of 0.5 mm introduced with respect to nominal offset assumed in Optimal control allocation scheme. Regarding the mechanical plant, the mechanical plant model includes external pulsed disturbance, random disturbance (Gaussian), and frictional disturbance that includes friction-striction modeled using Stribeck friction law. Control gain is derated with respect to the assumed value in Friction Compensator and Current Control Module.

[0153] FIGS. 21 A-21P are graphs of simulation results, according to embodiments of the disclosure. Referring to FIG. 21 A, reference numeral 2101 shows the external pulsed disturbance applied. This simulates the high-bandwidth disturbance experienced by the carrier / magnet when moving across discontinuities at track segment junctions, fluid spills, contamination of riding surface, etc. Referring to FIG. 21 B, note that the friction is modeled according to Stribeck model. FIGS. 21C-21F show graphs of the simulation’s optimal control allocation. Optimal control allocation identifies the coils that are activated at any given timeand computes the reference current inputs for the active coils. Referring specifically to FIG. 21E, the resulting voltage and coil-current references are plotted. Note that coil voltage is limited to 36V maximum. FIGS. 21G and 21H show the simulation’s motion response, i.e., position and velocity trajectories. As illustrated in these graphs, the method proposed herein achieves good positioning accuracy despite the presence of external disturbances, endogenous disturbances in the form of unmodeled dynamics, plant variation, and unmodeled frictional effects. FIGS. 211-21 J illustrate the simulation’s estimated state. A portion of the graph in FIG. 21 J is circled. This part of the graph shows that the pulsed disturbance (large bandwidth) results in velocity estimation error. The effect on the controller can be minimized by choosing a lower penalization velocity tracking in the LQR. FIGS. 21 K and 2 IL show the 2-DOF controller response, LQG feedback component of control (unsaturated) and the disturbance estimate-based friction compensation, respectively. Next, the pulse external disturbance is applied during the settle phase. FIGS. 21M-21P show the simulation’s pulsed disturbance during the settle phase. As noted in FIG. 210, the target position was acquired 0.4 secs later when pulsed disturbance is applied during settle phase. However, good settle response and very good motion control performance was achieved in simulations with endposition accuracy of < 0.15 mm achieved. Simulations demonstrated robustness of the proposed scheme in the presence of exogenous disturbances (high-bandwidth pulsed disturbance and unmodeled frictional effects) along with unmodeled dynamics and plant variations.

[0154] FIG. 22 illustrates an exemplary computing environment 2200 within which embodiments of the invention may be implemented. For example, this computing environment 2200 may be configured to execute a method of placing an item having irregular dimensions. The computing environment 2200 may include computer system 2210, which is one example of a computing system upon which embodiments of the invention may be implemented. Computers and computing environments, such as computer system 2210 and computing environment 2200, are known to those of skill in the art and thus are described briefly here. It is worth noting again that the description of a 3-phase drive architecture with active 2-phase optimal control allocation is for exemplary purposes only. The schemes disclosed herein can be applied to more generic polyphase drive systems.

[0155] As shown in FIG. 22, the computer system 2210 may include a communication mechanism such as a bus 2205 or other communication mechanism for communicating information within the computer system 2210. The computer system 2210 further includes one or more processors 2220 coupled with the bus 2205 for processing the information. Theprocessors 2220 may include one or more central processing units (CPUs), graphical processing units (GPUs), or any other processor known in the art.

[0156] The computer system 2210 also includes a system memory 2230 coupled to the bus 2205 for storing information and instructions to be executed by processors 2220. The system memory' 2230 may include computer readable storage media in the form of volatile and / or nonvolatile memory’, such as read only memory (ROM) 2231 and / or random-access memory (RAM) 2232. The system memory RAM 2232 may include other dynamic storage device(s) (e.g., dynamic RAM, static RAM, and synchronous DRAM). The system memory ROM 2231 may include other static storage device(s) (e.g., programmable ROM, erasable PROM, and electrically erasable PROM). In addition, the system memory' 2230 may be used for storing temporary’ variables or other intermediate information during the execution of instructions by the processors 2220. A basic input / output system (BIOS) 2233 containing the basic routines that help to transfer information between elements within computer system 2210, such as during start-up, may be stored in ROM 2231. RAM 2232 may contain data and / or program modules that are immediately accessible to and / or presently being operated on by the processors 2220. System memory 2230 may additionally include, for example, operating system 2234, application programs 2235, other program modules 2236 and program data 2237.

[0157] The computer system 2210 also includes a disk controller 2240 coupled to the bus 2205 to control one or more storage devices for storing information and instructions, such as a hard disk 2241 and a removable media drive 2242 (e g., floppy disk drive, compact disc drive, tape drive, and / or solid state drive). The storage devices may be added to the computer system 2210 using an appropriate device interface (e.g., a small computer system interface (SCSI), integrated device electronics (IDE), Universal Serial Bus (USB), or FireWire).

[0158] The computer system 2210 may also include a display controller 2265 coupled to the bus 2205 to control a display 2266, such as a cathode ray tube (CRT) or liquid crystal display (LCD), for displaying information to a computer user. The computer system 2210 includes an input interface 2260 and one or more input devices, such as a keyboard 2262 and a pointing device 2261, for interacting with a computer user and providing information to the processor 2220. The pointing device 2261, for example, may be a mouse, a trackball, or a pointing stick for communicating direction information and command selections to the processor 2220 and for controlling cursor movement on the display 2266. The display 2266 may provide a touch screen interface which allows input to supplement or replace thecommunication of direction information and command selections by the pointing device 2261.

[0159] The computer system 2210 may perform a portion or all of the processing steps of embodiments of the invention in response to the processors 2220 executing one or more sequences of one or more instructions contained in a memory, such as the system memory 2230. Such instructions may be read into the system memory 2230 from another computer readable medium, such as a hard disk 2241 or a removable media drive 2242. The hard disk 2241 may contain one or more datastores and data files used by embodiments of the present invention. Datastore contents and data files may be encrypted to improve security. The processors 2220 may also be employed in a multi-processing arrangement to execute the one or more sequences of instructions contained in system memory 2230. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions. Thus, embodiments are not limited to any specific combination of hardware circuitry7and software.

[0160] As stated above, the computer system 2210 may include at least one computer readable medium or memory for holding instructions programmed according to embodiments of the invention and for containing data structures, tables, records, or other data described herein. The term “computer readable medium" as used herein refers to any medium that participates in providing instructions to the processor 2220 for execution. A computer readable medium may take many forms including, but not limited to, non-volatile media, volatile media, and transmission media. Non-limiting examples of non-volatile media include optical disks, solid state drives, magnetic disks, and magneto-optical disks, such as hard disk 2241 or removable media drive 2242. Non-limiting examples of volatile media include dynamic memory’, such as system memory’ 2230. Non-limiting examples of transmission media include coaxial cables, copper wire, and fiber optics, including the wires that make up the bus 2205. Transmission media may also take the form of acoustic or light waves, such as those generated during radio wave and infrared data communications.

[0161] The computing environment 2200 may further include the computer system 2210 operating in a networked environment using logical connections to one or more remote computers, such as remote computer 2280. Remote computer 2280 may be a personal computer (laptop or desktop), a mobile device, a server, a router, a network PC, a peer device or other common network node, and ty pically includes many or all of the elements described above relative to computer system 2210. When used in a networking environment, computer system 2210 may include modem 2272 for establishing communications over a network2271, such as the Internet. Modem 2272 may be connected to bus 2205 via user network interface 2270. or via another appropriate mechanism.

[0162] Network 2271 may be any network or system generally known in the art, including the Internet, an intranet, a local area network (LAN), a wide area network (WAN), a metropolitan area network (MAN), a direct connection or series of connections, a cellular telephone network, or any other network or medium capable of facilitating communication between computer system 2210 and other computers (e.g., remote computer 2280). The network 2271 may be wired, wireless or a combination thereof. Wired connections may be implemented using Ethernet, Universal Serial Bus (USB), RJ-11 or any other wired connection generally known in the art. Wireless connections may be implemented using WiFi, WiMAX, and Bluetooth, infrared, cellular networks, satellite or any other wireless connection methodology generally known in the art. Additionally, several networks may work alone or in communication with each other to facilitate communication in the network 2271.

[0163] The embodiments of the present disclosure may be implemented with any combination of hardware and software. In addition, the embodiments of the present disclosure may be included in an article of manufacture (e g., one or more computer program products) having, for example, computer-readable, non-transitory media. The media has embodied therein, for instance, computer readable program code for providing and facilitating the mechanisms of the embodiments of the present disclosure. The article of manufacture can be included as part of a computer system or sold separately.

[0164] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

[0165] An executable application, as used herein, comprises code or machine readable instructions for conditioning the processor to implement predetermined functions, such as those of an operating system, a context data acquisition system or other information processing system, for example, in response to user command or input. An executable procedure is a segment of code or machine readable instruction, sub-routine, or other distinct section of code or portion of an executable application for performing one or more particular processes. These processes may include receiving input data and / or parameters, performing operations on received input data and / or performing functions in response to received input parameters, and providing resulting output data and / or parameters.

[0166] A graphical user interface (GUI), as used herein, comprises one or more display images, generated by a display processor and enabling user interaction with a processor or other device and associated data acquisition and processing functions. The GUI also includes an executable procedure or executable application. The executable procedure or executable application conditions the display processor to generate signals representing the GUI displayimages. These signals are supplied to a display device which displays the image for viewing by the user. The processor, under control of an executable procedure or executable application, manipulates the GUI display images in response to signals received from the input devices. In this way, the user may interact with the display image using the input devices, enabling user interaction with the processor or other device.

[0167] The functions and process steps herein may be performed automatically or wholly or partially in response to user command. An activity (including a step) performed automatically is performed in response to one or more executable instructions or device operation without user direct initiation of the activity7.

[0168] While various illustrative embodiments incorporating the principles of the present teachings have been disclosed, the present teachings are not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the present teachings and use its general principles. Further, this application is intended to cover such departures from the present disclosure that are within known or customary practice in the art to which these teachings pertain.

[0169] In the above detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identity7similar components, unless context dictates otherwise. The illustrative embodiments described in the present disclosure are not meant to be limiting. Other embodiments may be used, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that various features of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

[0170] Aspects of the present technical solutions are described herein with reference to flowchart illustrations and / or block diagrams of methods, apparatuses (systems), and computer program products according to embodiments of the technical solutions. It will be understood that each block of the flowchart illustrations and / or block diagrams, andcombinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer readable program instructions.

[0171] These computer readable program instructions can be provided to a processor of a general-purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks. These computer readable program instructions can also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and / or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function / act specified in the flowchart and / or block diagram block or blocks.

[0172] The computer readable program instructions can also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0173] The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present technical solutions. In this regard, each block in the flowchart or block diagrams can represent a module, segment, or portion of instructions, which includes one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the blocks can occur out of the order noted in the figures. For example, two blocks show n in succession can, in fact, be executed substantially concurrently, or the blocks can sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustration, and combinations of blocks in the block diagrams and / or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or cany' out combinations of special purpose hardware and computer instructions.

[0174] A second action can be said to be "in response to” a first action independent of whether the second action results directly or indirectly from the first action. The secondaction can occur at a substantially later time than the first action and still be in response to the first action. Similarly, the second action can be said to be in response to the first action even if intervening actions take place between the first action and the second action, and even if one or more of the intervening actions directly cause the second action to be performed. For example, a second action can be in response to a first action if the first action sets a flag and a third action later initiates the second action whenever the flag is set.

[0175] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various features. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds, compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

[0176] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity.

[0177] It will be understood by those within the art that, in general, terms used herein are generally intended as “open” terms (for example, the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least.” the term “includes” should be interpreted as “includes but is not limited to,” et cetera). While various compositions, methods, and devices are described in terms of “comprising” various components or steps (interpreted as meaning “including, but not limited to”), the compositions, methods, and devices can also “consist essentially of’ or “consist of’ the various components and steps, and such terminology should be interpreted as defining essentially closed-member groups.

[0178] As used in this document, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Nothing in this disclosure is to be construed as anadmission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention.

[0179] In addition, even if a specific number is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (for example, the bare recitation of "tw o recitations," without other modifiers, means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "‘at least one of A, B. and C, et cetera” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “a system having at least one of A, B, and C” w ould include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B. and C together, et cetera). In those instances where a convention analogous to '‘at least one of A, B, or C, et cetera” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, "a sy stem having at least one of A, B, or C” w ould include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together. B and C together, and / or A, B. and C together, et cetera). It will be further understood by those within the art that virtually any disjunctive w ord and / or phrase presenting tw o or more alternative terms, whether in the description, sample embodiments, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of '‘A” or “B” or ‘’A and B.”

[0180] In addition, w here features of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0181] As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a w ritten description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily- recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, et cetera. As a non-limiting example, each range discussed herein can be readily broken down into a low er third, middle third and upper third, et cetera. As will also be understood by one skilled in the art all language such as “up to,” “at least,” and the like include the number recited and refer to ranges that can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, agroup having 1-3 components refers to groups having 1, 2, or 3 components. Similarly, a group having 1-5 components refers to groups having 1, 2, 3, 4. or 5 components, and so forth.

[0182] Various of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.NON-LIMITING ILLUSTRATIVE EMBODIMENTS

[0183] Illustrative embodiment 1. A vessel transport system in a liquid handler system, the vessel transport system comprising: a vessel mover configured to transport a sample vessel and having a magnetic base; a track comprising a poly-phase drive comprising n number of phases and configured to provide a plurality of selective magnetic fields to propel the magnetic base of the vessel mover along the track, wherein each phase is configured to provide current to one of a plurality of coils comprising n number of coils; and a processor configured to: control selective application of currents to the track to create the plurality of selective magnetic fields using n-1 of the plurality of coils, wherein one or more coils receiving current are one or more active coils and at least one coil not receiving current is an inactive coil, and receive back electromagnetic field (BEMF) measurements from the inactive coil and use the BEMF measurements to determine one or more of a vessel mover's position and velocity.

[0184] Illustrative embodiment 2. The vessel transport system of illustrative embodiment 1, wherein the processor is further configured to: determine the one or more active coils.

[0185] Illustrative embodiment 3. The vessel transport system according to one of the preceding illustrative embodiments, wherein the track further comprises comprising a plurality of multilayer printed circuit boards (PCB) arranged along a transport path, each PCB having a plurality of multi-layer conductive coils within layers of the PCB, each coil comprising a plurality of single-layer spirals electrically coupled with one another to form a multilayer coil, and wherein determining the one or more active coils comprises: determining a plurality of track coils proximate the vessel mover; determining a subset of proximate coils, wherein the subset of proximate coils comprise coils that, if activated, would cause one ormore magnetic fields to propel the magnetic base forward; and determine the one or more coils by determining one or more coils that correspond with the subset of the proximate coils.

[0186] Illustrative embodiment 4. The vessel transport system according to one of the preceding illustrative embodiments, wherein determining the one or more coils proximate each of the vessel movers comprises: sensing, from the magnetic base of the vessel mover, a magnetic field.

[0187] Illustrative embodiment 5. The vessel transport system according to one of the preceding illustrative embodiments, wherein determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises: determining one or more coils of the subset of proximate coils that, if activated, would attract a front end of the vessel mover.

[0188] Illustrative embodiment 6. The vessel transport system according to one of the preceding illustrative embodiments, wherein determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises: determining one or more coils of the subset of proximate coils that, if activated, would repel a back end of the vessel mover.

[0189] Illustrative embodiment 7. The vessel transport system according to one of the preceding illustrative embodiments, wherein the processor is further configured to: determine an amount of current of each of the active coils.

[0190] Illustrative embodiment 8. The vessel transport system according to one of the preceding illustrative embodiments, wherein the determined amount of current comprises a maximum input current for each of the active coils.

[0191] Illustrative embodiment 9. The vessel transport system according to one of the preceding illustrative embodiments, wherein determining the amount of current of each of the active coils comprises: calculating the determined amount of current using a constrained optimization problem, wherein an objective function of the constrained optimization problem comprises minimizing a w eighted sum of the squared determined amounts of current and a constraint of the constrained optimization problem comprises a required force to propel the magnetic base and limits on the current inputs to each active coil.

[0192] Illustrative embodiment 10. The vessel transport system according to one of the preceding illustrative embodiments, wherein the track further comprises a plurality of Hall effect sensors and the processor is further configured to also use signals from the plurality of Hall effect sensors to determine one or more of a vessel mover’s position and velocity.

[0193] Illustrative embodiment 11. A computer-implemented method for moving a vessel mover along a track and sensing the vessel mover’s position and velocity, the vessel mover having a magnetic base and the track having a poly -phase drive comprising n number of phases and configured to provide a plurality of selective magnetic fields to propel the magnetic base of the vessel mover along the track, wherein each phase is configured to provide current to one of a plurality of coils comprising n number of coils, the method comprising, iteratively: controlling selective application of currents to the track to create the plurality of selective magnetic fields using n-1 the plurality of coils, wherein one or more coils receiving current are one or more active coils and at least one coil not receiving current is an inactive coil; receiving BEMF measurements from the inactive coil: and determining one or more of the vessel mover’s position and velocity using the received BEMF measurements.

[0194] Illustrative embodiment 12. A computer-implemented method according to one of the preceding illustrative embodiments, further comprising: determining the one or more active coils.

[0195] Illustrative embodiment 13. A computer-implemented method according to one of the preceding illustrative embodiments, wherein the track further comprises a plurality of multilayer printed circuit boards (PCB) arranged along a transport path, each PCB having a plurality of multi-layer conductive coils within layers of the PCB, each coil comprising a plurality of single-layer spirals electrically coupled with one another to form a multilayer coil, and determining the one or more active coils comprises: determining one or more coils proximate the vessel mover; determining a subset of proximate coils, wherein the subset of proximate coils comprise coils that, if activated, would cause one or more magnetic fields to propel the magnetic base forward; and determining the one or more active coils by determining the one or more coils that correspond with the subset of the proximate coils.

[0196] Illustrative embodiment 14. The computer-implemented method of according to one of the preceding illustrative embodiments, wherein determining the one or more coils proximate each of the vessel movers comprises: sensing, from the magnetic base of the vessel mover, a magnetic field.

[0197] Illustrative embodiment 15. The computer-implemented method according to one of the preceding illustrative embodiments, wherein determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises: determining one or more coils of the subset of proximate coils that, if activated, would attract a front end of the vessel mover.

[0198] Illustrative embodiment 16. The computer-implemented method according to one of the preceding illustrative embodiments, wherein determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises: determining one or more coils of the subset of proximate coils that, if activated, w ould repel a back end of the vessel mover.

[0199] Illustrative embodiment 17. The computer-implemented method o according to one of the preceding illustrative embodiments, further comprises: determining an amount of current of each of the one or more active coils.

[0200] Illustrative embodiment 18. The computer-implemented method according to one of the preceding illustrative embodiments, w herein determining the amount of current of each of the active coils comprises: calculating the determined amount of current using a constrained optimization problem, wherein an objective function of the constrained optimization problem comprises minimizing a weighted sum of the squared determined amounts of current and a constraint of the constrained optimization problem comprises a required force to propel the magnetic base.

[0201] Illustrative embodiment 19. The computer-implemented method according to one of the preceding illustrative embodiments, wherein no two active coils are adjacent.

[0202] Illustrative embodiment 20. A computer program product configured to perform a processor for moving a vessel mover along a track and sensing the vessel mover's position and velocity, the computer program product comprising a computer readable storage medium having program instructions embodied therewith, the program instructions executable by a processor to cause the processor to: controlling selective application of currents to the track to create one or more magnetic fields using n-1 of phases of a poly-phase drive, w herein each phase of the poly-phase drive is configured to provide current to one of a plurality of coils comprising n number of coils, wherein one or more coils receiving current are one or more active coils and at least one coil not receiving current is an inactive coil; and receive BEMF measurements from the inactive coil; and determining one or more of the vessel mover’s position and velocity using the received BEMF measurements.

Claims

CLAIMSWe claim:

1. A vessel transport system in a liquid handler system, the vessel transport system comprising: a vessel mover configured to transport a sample vessel and having a magnetic base; a track comprising a poly-phase drive comprising n number of phases and configured to provide a plurality of selective magnetic fields to propel the magnetic base of the vessel mover along the track, wherein each phase is configured to provide current to one of a plurality of coils comprising n number of coils; and a processor configured to: control selective application of currents to the track to create the plurality of selective magnetic fields using n- \ of the plurality of coils, wherein one or more coils receiving current are one or more active coils and at least one coil not receiving current is an inactive coil, and receive back electromagnetic field (BEMF) measurements from the inactive coil and use the BEMF measurements to determine one or more of a vessel mover’s position and velocity.

2. The vessel transport system of claim 1. wherein the processor is further configured to: determine the one or more active coils.

3. The vessel transport system of claim 2, wherein the track further comprises comprising a plurality of multilayer printed circuit boards (PCB) arranged along a transport path, each PCB having a plurality of multilayer conductive coils within layers of the PCB, each coil comprising a plurality of singlelayer spirals electrically coupled with one another to form a multilayer coil, and wherein determining the one or more active coils comprises: determining a plurality of track coils proximate the vessel mover; determining a subset of proximate coils, wherein the subset of proximate coils comprise coils that, if activated, w ould cause one or more magnetic fields to propel the magnetic base forward; and determine the one or more coils by determining one or more coils that correspond with the subset of the proximate coils.

4. The vessel transport system of claim 3. wherein determining the one or more coils proximate each of the vessel movers comprises: sensing, from the magnetic base of the vessel mover, a magnetic field.

5. The vessel transport system of claim 3. wherein determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises: determining one or more coils of the subset of proximate coils that, if activated, would attract a front end of the vessel mover.

6. The vessel transport system of claim 3, wherein determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises: determining one or more coils of the subset of proximate coils that, if activated, would repel a back end of the vessel mover.

7. The vessel transport system of claim 1, wherein the processor is further configured to: determine an amount of current of each of the active coils.

8. The vessel transport system of claim 7, wherein the determined amount of current comprises a maximum input current for each of the active coils.

9. The vessel transport system of claim 7. wherein determining the amount of current of each of the active coils comprises: calculating the determined amount of current using a constrained optimization problem, wherein an objective function of the constrained optimization problem comprises minimizing a weighted sum of the squared determined amounts of current and a constraint of the constrained optimization problem comprises a required force to propel the magnetic base and limits on the current inputs to each active coil.

10. The vessel transport system of claim 1, wherein the track further comprises a plurality of Hall effect sensors and the processor is further configured to also use signals from theplurality of Hall effect sensors to determine one or more of a vessel mover's position and velocity.

11. A computer-implemented method for moving a vessel mover along a track and sensing the vessel mover’s position and velocity, the vessel mover having a magnetic base and the track having a poly-phase drive comprising n number of phases and configured to provide a plurality of selective magnetic fields to propel the magnetic base of the vessel mover along the track, wherein each phase is configured to provide current to one of a plurality of coils comprising n number of coils, the method comprising, iteratively: controlling selective application of currents to the track to create the plurality of selective magnetic fields using n-1 the plurality of coils, wherein one or more coils receiving current are one or more active coils and at least one coil not receiving current is an inactive coil; receiving BEMF measurements from the inactive coil; and determining one or more of the vessel mover’s position and velocity using the received BEMF measurements.

12. A computer-implemented method of claim 11, further comprising: determining the one or more active coils.

13. A computer-implemented method of claim 12, wherein the track further comprises a plurality of multilayer printed circuit boards (PCB) arranged along a transport path, each PCB having a plurality' of multi-layer conductive coils within layers of the PCB, each coil comprising a plurality of single-layer spirals electrically coupled with one another to form a multilayer coil, and determining the one or more active coils comprises: determining one or more coils proximate the vessel mover; determining a subset of proximate coils, wherein the subset of proximate coils comprise coils that, if activated, would cause one or more magnetic fields to propel the magnetic base forward; and determining the one or more active coils by determining the one or more coils that correspond with the subset of the proximate coils.

14. The computer-implemented method of claim 13, wherein determining the one or more coils proximate each of the vessel movers comprises:sensing, from the magnetic base of the vessel mover, a magnetic field.

15. The computer-implemented method of claim 13, wherein determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises: determining one or more coils of the subset of proximate coils that, if activated, would attract a front end of the vessel mover.

16. The computer-implemented method of claim 13, wherein determining the subset of proximate coils that, if activated, would cause the plurality of selective magnetic fields to propel the magnetic base forward comprises: determining one or more coils of the subset of proximate coils that, if activated, would repel a back end of the vessel mover.

17. The computer-implemented method of claim 11, further comprises: determining an amount of current of each of the one or more active coils.

18. The computer-implemented method of claim 17, wherein determining the amount of current of each of the active coils comprises: calculating the determined amount of current using a constrained optimization problem, wherein an objective function of the constrained optimization problem comprises minimizing a weighted sum of the squared determined amounts of current and a constraint of the constrained optimization problem comprises a required force to propel the magnetic base.

19. The computer-implemented method of claim 11, wherein no two active coils are adjacent.

20. A computer program product configured to perform a processor for moving a vessel mover along a track and sensing the vessel mover's position and velocity, the computer program product comprising a computer readable storage medium having program instructions embodied therewith, the program instructions executable by a processor to cause the processor to: controlling selective application of currents to the track to create one or more magnetic fields using n- of phases of a poly-phase drive, wherein each phase of the polyphase drive is configured to provide current to one of a plurality of coils comprising n number of coils, wherein one or more coils receiving current are one or more active coils and at least one coil not receiving current is an inactive coil; and receive BEMF measurements from the inactive coil; and determining one or more of the vessel mover’s position and velocity' using the received BEMF measurements.

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