Devices and methods for transporting sample carriers in diagnostic laboratory systems

Abstract

A method of operating a diagnostic laboratory system includes providing a first sample carrier and a second sample carrier that are each asynchronously movable on a track. The first and second sample carriers each have at least one movement characteristic. Locations of the first and second sample carriers are identified, and a first route is generated to move the first sample carrier from the first location to a first destination and a second route is generated to move the second sample carrier from the second location to a second destination. A determination is made as to whether a sample carrier conflict exists in the routes. In response to determining that a sample carrier conflict exists, at least one movement dependency is identified in the routes to prevent sample carrier collisions. Other methods and systems are disclosed.

Description

DEVICES AND METHODS FOR TRANSPORTING SAMPLE CARRIERS IN DIAGNOSTIC LABORATORY SYSTEMSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit claims benefit under 35 USC § 119(e) of U.S. Provisional Patent Application No. 63 / 552,800, filed on February 13, 2024, the disclosure of which is hereby incorporated by reference herein in its entirety.FIELD

[0002] The present disclosure relates to devices and methods for transporting sample carriers in diagnostic laboratory systems.BACKGROUND

[0003] Diagnostic laboratory systems conduct clinical chemistry or assays to identify analytes or other constituents in biological samples such as blood serum, blood plasma, urine, interstitial liquid, cerebrospinal liquids, and the like. The samples may be received in and / or transported throughout the laboratory systems in sample containers. Many of the laboratory systems simultaneously process large numbers of sample containers and the samples contained therein.

[0004] Some diagnostic laboratory systems include a plurality of diagnostic instruments that process and test the samples. Such diagnostic laboratory systems may include tracks interconnecting the diagnostic instruments. The tracks may be configured to move the sample containers by way of sample carriers. The track enables the sample carriers to move by way of a plurality of different paths or routes extending between the diagnostic instruments. The sample carriers may be susceptible to collisions when two sample carriers are directed to move in different directions and / or different speeds on the same portion of the track. Accordingly, systems and methods that provide sample carrier transportation throughout a laboratory system that avoid sample carrier collisions are sought.SUMMARY

[0005] According to a first aspect, a method of operating a diagnostic laboratory system is provided. The method includes providing a first sample carrier movable on a track in the diagnostic laboratory system, wherein the first sample carrier has at least one first movement characteristic and the track extends between a plurality of instruments; providing a second sample carrier movable on the track, wherein the second sample carrier has at least one second movement characteristic and the first and second sample carriers are movable independently of each other; identifying a first location of the first sample carrierand a second location of the second sample carrier; generating a first route to move the first sample carrier from the first location to a first destination; generating a second route to move the second sample carrier from the second location to a second destination; determining if a sample carrier conflict exists between the first and second routes; and identifying at least one dependency in the first route or the second route in response to the determining indicating that a sample carrier conflict exists, wherein the at least one dependency makes movement of the first sample carrier dependent on movement of the second sample carrier.

[0006] In another aspect, a diagnostic laboratory system for analyzing a biological sample is provided. The system includes a plurality of instruments; a track located in the diagnostic laboratory system, wherein the track extends between the plurality of instruments; a first sample carrier movable on the track, wherein the first sample carrier has at least one first movement characteristic; a second sample carrier movable on the track, wherein the second sample carrier has at least one second movement characteristic and the first and second sample carriers are movable independently of each other. The system also includes a computer having instructions executable to: identify a first location of the first sample carrier; identify a second location of the second sample carrier; generate a first route to move the first sample carrier from the first location to a first destination which, in some embodiments, is based at least in part on the at least one first movement characteristic; generate a second route to move the second sample carrier from the second location to a second destination which, in some embodiments, is based at least in part on the at least one second movement characteristic; determine if a sample carrier conflict exists between the first and second routes; identify at least one dependency in the first route or the second route in response to determining that a sample carrier conflict exists, wherein the at least one dependency makes movement of the first sample carrier dependent on movement of the second sample carrier; execute the first and second routes and monitor positions of the first and second carriers; and in response to monitoring that the first or second route did not complete successfully, determine whether the first or second route needs to be replanned.

[0007] In a further aspect, a method of moving a first sample carrier and a second sample carrier in a diagnostic laboratory system is provided. The method includes providing a track in the diagnostic laboratory system, wherein the track extends between a plurality of instruments; providing a first sample carrier movable on the track, wherein the first sample carrier is self-propelled and is movable at a first velocity; providing a second sample carrier movable on the track, wherein the second sample carrier is self-propelled and is movable at a second velocity, and wherein the first velocity is different than the second velocity; identifying a first location of the first sample carrier; identifying a second location of the second sample carrier; generating a first route to move the first sample carrier from the first location to a first destination based at least in part on the first velocity; generating a secondroute to move the second sample carrier from the second location to a second destination based at least in part on the second velocity; determining if a sample carrier conflict exists between the first route and the second route; identifying at least one dependency in response to the determining that a sample carrier conflict exists, wherein the at least one dependency comprises directing the first sample carrier to wait while directing the second sample carrier to move; and executing the first and second routes.

[0008] Still other aspects, features, and advantages of this disclosure may be readily apparent from the following description and illustration of a number of example embodiments, including the best mode contemplated for carrying out the disclosure. This disclosure may also be capable of other and different embodiments, and its several details may be modified in various respects, all without departing from the scope of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

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

[0010] FIG. 1 A illustrates a block diagram of a diagnostic laboratory system according to one or more embodiments.

[0011] FIG. 1 B illustrates an enlarged portion of a track of the diagnostic laboratory system of FIG. 1 A according to one or more embodiments.

[0012] FIG. 1C illustrates an enlarged portion of the track of FIG. 1B showing individual blocks or transportation components according to one or more embodiments.

[0013] FIG. 1 D illustrates an isometric enlarged view of a portion of the track of FIG. 1 A including two sample carriers holding sample containers, wherein the sample carriers are asynchronously movable relative to each other according to one or more embodiments.

[0014] FIG. 1 E illustrates a side elevation view of one of the sample carriers and sample containers of FIG. 1 D according to one or more embodiments.

[0015] FIG. 1 F illustrates an isometric enlarged view of a portion of the track of FIG. 1A including two sample carriers holding sample containers, wherein the sample carriers are asynchronously movable relative to each other by way of linear motors according to one or more embodiments.

[0016] FIG. 1G illustrates a side elevation view of one of the sample carriers and sample containers of FIG. 1 F according to one or more embodiments.

[0017] FIG. 2A illustrates sample containers located in certain blocks on a track of a laboratory system at a time t=0 according to one or more embodiments.

[0018] FIG. 2B illustrates the sample containers of FIG. 2A after an incremental time t=1 , wherein the sample containers have synchronously moved to different ones of the blocks according to one or more embodiments.

[0019] FIG. 3A illustrates a block diagram representing an embodiment of the track of the diagnostic laboratory system of FIG. 1A as a plurality of adjacent blocks according to one or more embodiments.

[0020] FIGS. 3B-3E illustrate enlarged views of certain ones of the blocks of the diagnostic laboratory system of FIG. 1A and the block diagram of FIG. 3A according to one or more embodiments.

[0021] FIG. 4A illustrates a portion of the track of FIG. 3A with sample containers moving to different destinations according to one or more embodiments.

[0022] FIG. 4B illustrates a dependency graph generated to avoid sample carrier conflicts in the sample container routing of FIG. 4A according to one or more embodiments.

[0023] FIG. 5 illustrates a flowchart of a method of operating the laboratory system of FIG. 1 A to avoid sample carrier conflicts according to one or more embodiments.

[0024] FIG. 6 illustrates a portion of the track of FIG. 3A wherein sample carriers are moving toward each other and may collide according to one or more embodiments.

[0025] FIG. 7 illustrates three-dimensional blocks representative of a portion of a track in a diagnostic laboratory system that may move sample carriers in three dimensions according to one or more embodiments.

[0026] FIG. 8 illustrates a flowchart describing a method of operating a diagnostic laboratory system according to one or more embodiments.

[0027] FIG. 9 illustrates a flowchart describing a method of moving a first sample carrier and a second sample carrier in a diagnostic laboratory system according to one or more embodiments.DETAILED DESCRIPTION

[0028] Independent of the grammatical term usage, individuals with male, female or other gender identities are included within the term.

[0029] Automated diagnostic laboratory systems (laboratory systems) may transport sample containers to different instruments or other destinations within the laboratory system via tracks. The track may provide a plurality of different routes or paths for the sample containers to move between different instruments, wherein the different instruments perform various processes or tests on samples located in the sample containers. A routing program may determine routes that each of the sample containers take to reach the instruments. The routing becomes more complex as more sample types and testing capabilities are added to the laboratory systems. For example, sample containers may have to pass one another oryield to one another at certain times and / or locations on the track to arrive at specific instruments at specific times. The routing becomes even more complex when high priority samples are added to the laboratory system because the routing must be updated so that low priority samples yield to the high priority samples.

[0030] Some laboratory systems use sample carriers to transport the sample containers throughout the laboratory systems. The sample carriers may move asynchronously relative to each other, which means the sample carriers move independently of each other. For example, some sample carriers may be self-propelled, so each sample carrier may have different movement characteristics such as different accelerations and velocities. The different movement characteristics may further complicate the route planning.

[0031] Diagnostic laboratory systems may be arranged in different physical configurations (e.g., different layouts of the track and different instruments), so the routing programs generally must be customized to the specific diagnostic laboratory configurations employed. However, customizing routing programs for each different configuration is difficult and increases the costs of implementing diagnostic laboratory systems.

[0032] The laboratory systems and methods described herein support asynchronous movement of the sample carriers throughout the laboratory systems. An original routing plan may be generated based on synchronous movement of the sample carriers. The original routing plan may be converted or adapted to asynchronous movement of the sample carriers according to one or more embodiments described herein. In some embodiments, the asynchronous movement of the sample carriers may be executed with unknown or unforeseen sample carrier conflicts, such as potential collisions and / or objects blocking the routes of the sample carriers. The laboratory systems and methods may trigger a replanning process when the sample carrier conflicts are identified in real time via position sensors, feedback from the sample carriers, and / or track and instrument operational status received at a system controller. The sample carrier conflicts may arise when new sample containers are added to a laboratory system. For example, the newly-added sample containers may need to move in such ways that the newly-added sample containers may conflict (e.g., possibly collide) with sample containers already present on the track.

[0033] Embodiments of diagnostic laboratory systems and routing methods described herein may use dynamic routing algorithms to generate routes to transport sample containers on one or more tracks throughout the laboratory systems. For illustrative purposes, each track may be represented as small segments or blocks, wherein each block represents a portion of the track configured to hold one sample carrier or a limited number of sample carriers. For further illustrative purposes, movement and tracking of the sample carriers may be based initially on movement of the sample carriers between adjacent blocksrather than over the entire track. The sample carriers may move independently (e.g., asynchronously) relative to each other between and through the blocks. A routing program may generate routes that cause the sample carriers to arrive at specific destinations at specific times. For example, the routing program may determine when certain sample carriers move, how far the sample carriers move, how fast the sample carriers move, and how long the sample carriers wait at specific locations on the track.

[0034] Each block may have movement constraints (e.g., up, down, left, right) associated therewith that indicate the directions the sample carriers may move into and / or out of the individual blocks. For example, certain blocks may only receive sample carriers from the left and pass them to the right one at a time to an adjacent block (e.g., a destination block). Intersection blocks may, for example, receive sample carriers from the left and exit them either to the right or down to an adjacent destination block. If it is determined that movement from one block to an adjacent destination block will cause a sample carrier conflict, the routing plan may be revised to include a movement dependency to avoid the sample carrier conflict as described herein.

[0035] When a sample container is introduced into a laboratory system, the sample container is loaded into a sample carrier. The sample carrier is then directed to move to a certain set of destinations, such as a plurality of instruments. Examples of the instruments include centrifuges, chemistry analyzers, decappers, and storage / refrigeration modules. The destinations may be required to be visited in a particular sequence, such as a centrifuge followed by a decapper. The routing plan may require that the sample container be moved to some of these destinations within a time window. For example, a sample may need to be aspirated at an aspiration station within a fixed time after decapping.

[0036] The routing program may generate instructions that direct all the sample carriers to their respective destinations within specific time windows while ensuring that the sample carriers do not collide or encounter other obstacles. When samples are required to be at specific destinations within specific time windows, the sample carriers may be directed to areas proximate the destinations and may remain idle (e.g., wait) or hover around the areas. In some embodiments, the routes may be planned with an assumption that the routes will be executed synchronously wherein the sample carriers perform one action per timestep in sync with each other. The routing program according to one or more embodiments takes into consideration kinematic constraints of the transport system. That is, the routing program may modify or adjust the synchronously planned routes, which assume that every action takes a uniform amount of time, by considering higher order dynamics such as variations in sample carrier velocity and acceleration and track friction that may be encountered by the individual sample carriers.

[0037] Synchronous routing plans may be generated for moving sample carriers within a laboratory system, such as when sample carrier routing is based on movements of sample carriers into and out of individual track blocks. This route planning, however, may cause problems when the synchronous plans are executed by asynchronously moving sample carriers and may cause issues when the underlying synchronicity is violated. The violations may lead to potential collisions between sample carriers, exceeded time windows, and / or other sample carrier conflicts.

[0038] The laboratory systems and methods disclosed herein overcome the problems with synchronous routing plans executed asynchronously by providing an execution framework to detect potential problems in advance. The laboratory systems and methods disclosed herein generate routes for the sample carriers to move asynchronously on the track. As the routing plans change, such as by the addition of newly-received sample containers, the routes are updated. In addition, should a collision or other sample carrier conflict be predicted, the routes may be replanned to avert any sample carrier conflicts. These and other laboratory systems and methods are described in detail with reference to FIGS. 1-9.

[0039] Reference is now made to FIG. 1 A, which illustrates a diagram of an example embodiment of an automated diagnostic laboratory system 100 according to one or more embodiments. The laboratory system 100 may include a plurality of instruments 102 configured to process sample containers 104 (a few labelled) and to conduct assays or tests on biological samples contained in the sample containers 104. The laboratory system 100 includes a first sample container 104A located in a first sample carrier 108A and a second sample container 104B located in a second sample carrier 108B. The laboratory system 100 may include a first instrument 102A and a second instrument 102B. In addition, the laboratory system 100 may include a third instrument configured as a sample handler 102C. The sample handler 102C is configured to receive the sample containers 104 into the laboratory system 100 and to discharge sample containers from the laboratory system 100 after testing. The first instrument 102A and / or the second instrument 102B may perform analyses on the samples (e.g., sample 162A - FIG. 1 D) located in the sample containers 104. Other embodiments of the laboratory system 100 may include more or less instruments.

[0040] The samples located in the sample containers 104 may be various biological specimens collected from patients being evaluated by medical professionals. The samples may be collected from patients and placed into the sample containers 104. The sample containers 104 may then be delivered to the laboratory system 100. The sample containers 104 may be loaded into the sample handler 102C. From the sample handler 102C, the sample containers 104 may be transferred onto sample carriers 108 (a few labelled) thattransport the sample containers 104 throughout the laboratory system 100, such as to the instruments 102, by way of a track 110. Once a sample container is introduced into the laboratory system 100 and placed into a sample carrier, the sample carrier may be directed to visit a certain set of destinations (i.e., instruments 102 and / or other components) in a particular sequence. For example, a sample container may need to visit a centrifuge followed by a decapper. In some situations, some of the sample containers 104 may have to visit the destinations within a specific time window. For example, after decapping, a sample container 104 may have to be aspirated within a specific period of time.

[0041] The track 110 is configured to enable the sample carriers 108 to move throughout the laboratory system 100 including to and from the sample handler 102C in response to transport instructions described herein. For example, the track 110 may extend proximate and / or around at least some of the instruments 102 as shown in FIG. 1A. The instruments 102 may have devices, such as robots (not shown in FIG. 1A), that transfer the sample containers 104 to and from the sample carriers 108. The track 110 may have track sensors (not shown in FIG. 1A) that monitor the operational status of track switches / gates and tracks segments. The track 110 may also have electronic transport components (not shown in FIG. 1A) that move the sample containers 104 via the sample carriers 108 and / or monitor the locations of the sample carriers 108 on the track 110. In other embodiments, the sample carriers 108 may be self-propelled. For example, motors or the like within the sample carriers 108 may move the sample carriers 108 to preselected destinations within the laboratory system 100. In some embodiments, the sample carriers 108 may transmit their locations and / or operating parameters to a routing program as described herein.

[0042] The instruments 102, track sensors, and the transport components may include or be coupled to a computer 120, which may be a system controller. Computer 102 is configured to execute one or more programs that control operation of the laboratory system 100. The computer 120 may be configured to communicate with the instruments 102, the transport components, the sample carriers 108, and other components of the laboratory system 100. The computer 120 may include a processor 122 configured to execute programs including programs other than those described herein. The programs may be implemented in computer code. In some embodiments, the computer 120 may be remote from the instruments 102. Additionally, in some embodiments, the computer 120 may control the operation of a plurality of different laboratory systems. Thus, data generated by the laboratory system 100 may be stored and / or processed remotely from the laboratory system 100.

[0043] The computer 120 may include or have access to memory 124 that may store one or more programs and / or data described herein. The programs may include instructionsexecutable by the processor 122. In some embodiments, the memory may be remote from the other components of the computer 120. The memory 124 may be any suitable type of memory, such as, but not limited to one or more of a volatile memory and / or a non-volatile memory. The memory 124 may have a plurality of programs including computer instructions stored therein that, when executed by the processor 122, cause the processor 122 to perform various actions specified by one or more of the stored instructions. The instructions may be provided to the processor 122 to perform operations in accordance with the present systems and methods specified in the flowcharts and / or block diagrams described herein. The processor 122 so configured may become a special purpose machine particularly suited for performing in accordance with the present systems and methods. The instructions may be stored in a computer readable medium, such as the memory 124 that can direct the processor 122 to function in a particular manner. The term "memory" as used herein can refer to both non-transitory and transitory memory.

[0044] The memory 124 may include a routing program 126 (e.g., computer code executable by the processor 122) configured to generate routes (e.g, routing plans) for the sample containers 104 carried by the sample carriers 108 to move throughout the laboratory system 100. The routes may direct the sample containers 104 carried by the sample carriers 108 to specific ones of the instruments 102 to perform tests on or process samples in the sample containers 104. The memory 124 may include a sample carrier controller 128 configured to move the sample carriers 108 to preselected destinations in the laboratory system 100. Thus, the sample carrier controller 128 may direct the sample carriers 108 to move in preselected directions, at preselected speeds, and / or at preselected times. The sample carrier controller 128 also may generate instructions that direct certain components on the track 110 to activate to move the sample carriers 108 in specific directions and to specific destinations. For example, the sample carrier controller 128 may direct gates (not shown) and the like to move to preselected positions to divert sample carriers to specific destinations.

[0045] A workstation 132 may be electrically coupled to and in communication with the computer 120. In some embodiments, the workstation 132 may be remote from the track 110. The workstation 132 may include at least a display 134 and a keyboard 136. The workstation 132 enables users of the laboratory system 100 to input data to the computer 120 and enables the computer 120 to output data to the users, such as by the display 134.

[0046] The illustration of the track 110 includes dashed lines that show paths that the sample carriers 108 (and thus the sample containers 104) may take within the laboratory system 100. As shown in FIG. 1A, the sample carriers 108 may be able to take many routes on the paths throughout the laboratory system 100. The routing program 126 generatesinstructions that enable the sample carriers 108 to move on these paths to designated instruments and other destinations at scheduled times to keep the laboratory system 100 operating properly. In some embodiments, the routing program 126 may determine the most efficient routes for one or more of the sample carriers 108 given that there may be other sample carriers 108 travelling on the same path and / or to the same instruments. The sample carrier controller 128 may activate transport components (described below) on the track 110 that cause the sample carriers 108 to move via the routes determined by the routing program 126. The sample carrier controller 128 may also transmit movement instructions to the sample carriers 108 that direct self-propelled sample carriers 108 to move to specific destinations as described herein.

[0047] Additional reference is now made to FIG. 1 B, which illustrates an enlarged portion of the track 110. For illustration and description purposes, the track 110 is shown as having different segments 140 wherein the sample carriers 108 move in at least an x- direction and a y-direction and change directions between the x-direction and the y-direction on the segments 140. The types of segments 140 include curved segments 140A that change the directions of the sample carriers 108 between x-directions and y-directions and vice versa. Other types of segments 140 are intersection segments 1406 that receive the sample carriers 108 from a first port and selectively output the sample carriers 108 to one of at least two other ports. The intersection segments 1406 may also receive the sample carriers 108 from at least a first port and a second port and output the sample carriers 108 to a third port. The track 110 may also include straight segments 140C that continue motion of the sample carriers 108 in straight lines. Specific segments of the track 110 are described in detail below with reference to the operation of the routing program 126.

[0048] Individual ones of the segments 140 include a first segment 142 that is a straight segment extending in the x-direction. A second segment 144 is a curved segment extending in the y-direction and the x-direction. A third segment 146 is an intersection segment extending in the y-direction with a branch extending in the positive x-direction. A fourth segment 148 is another intersection segment extending in the x-direction with a branch extending in the negative y-direction. A fifth segment 150 is a curved segment and a sixth segment 152 is a curved segment that mirrors the fifth segment 150. A seventh segment 153 is parallel to the first segment 142.

[0049] Some embodiments of the track 110 may include transport mechanisms 154 (a few labelled) that are configured to transport the sample carriers 108 on the track 110 independently of each other. For example, the transport mechanisms 154 may move the sample carriers 108 asynchronously. Examples of the transport mechanisms 154 are described below with reference to FIGS. 1C-1G and may include movable belts and rollers(not separately shown) that use friction to move the sample carriers 108. Transport mechanisms 154 may include magnetic devices (see, FIGS. 1 F and 1G, for example) that magnetically move the sample carriers 108 relative to the track 110. In other examples, the sample carriers 108 may be self-propelled on the track 110 (e.g., see, FIG. 1 D, for example) and, in some embodiments, the sample carriers 108 that are self-propelled may receive movement instructions wirelessly from the computer 120 and / or the transport mechanisms 154. The transport mechanisms 154 are not limited to the examples described above. The transport mechanisms 154 may receive signals from the sample carrier controller 128 wherein the signals generated by the sample carrier controller 128 cause the transport mechanisms 154 to operate.

[0050] The laboratory system 100 may also include a plurality of position sensors 156 (a few labelled) configured to identify the positions of the sample containers 104 and / or the sample carriers 108 on the track 110. The position sensors 156 are illustrated as straight or curved rectangular shapes adjacent the segments 140 of the track 110. The position sensors 156 may be any devices that sense or determine the positions of the sample carriers 108 and / or the sample containers 104 and transmit the position information for processing by the routing program 126. In some embodiments, the position sensors 156 may be small individual elements located adjacent the track 110. Examples of the position sensors 156 include optical devices that read indicia (not shown) located on the sample carriers 108 and / or the sample containers 104, radio frequency identification devices (RFIDs) that read RFID tags (not shown) located on the sample carriers 108 and / or the sample containers 104, etc. Other embodiments of the position sensors 156 may include devices within or attached to the sample carriers 108. Other position sensors that determine positions of the sample containers 104 and / or the sample carriers 108 may be employed.

[0051] Additional reference is now made to FIG. 1C, which illustrates an enlarged portion of the track 110. The track 110 in FIG. 1C is represented by a plurality of blocks 160. The portion of the first segment 142 shown in FIG. 1C is illustrated as having four blocks that are referred to individually as a first block 160A, a second block 160B, a third block 160C, and a fourth block 160D. Other numbers of blocks 160 may be used. As described in greater detail below, the transport mechanisms 154 are configured to move the first sample carrier 108A (carrying the first sample container 104A) and the second sample carrier 108B (carrying the second sample container 104B) between adjacent blocks 160 asynchronously or independently of each other.

[0052] In the embodiment of FIG. 1C, the position sensor 156 is illustrated as being portioned into a plurality of individual sensors. Each of the sensors may be configured to sense the position of the first sample carrier 108A in each of the blocks 160 and transmit theposition information to the routing program 126. A first sensor 156A is configured to sense the first sample carrier 108A in the first block 160A, a second sensor 156B is configured to sense the second sample carrier 108B in the second block 160B, a third sensor 156C is configured to sense sample carriers 108 (FIG. 1A) in the third block 160C, and a fourth sensor 156D is configured to sense sample carriers 108 in the fourth block 160D.

[0053] The asynchronous movement of the sample carriers 108 (which may or may not be carrying respective sample containers 104) may be via linear motors or the like located within the sample carriers 108 and that receive signals and / or power applied to the sample carriers 108. For example, the transport mechanisms 154 may have hardware components configured to move the sample carriers 108 asynchronously between individual ones of the blocks 160. In the embodiment of FIG. 1C, the transport mechanisms 154 are moving the first sample carrier 108A from the first block 160A to the second block 160B and the second sample carrier 108B from the second block 160B to the third block 160C. In some embodiments, each of the blocks 160 may include an individual transport mechanism. In other embodiments, a plurality of the blocks 160 may be associated with a single transport mechanism, wherein the single transport mechanism is configured to transport the first sample carrier 108A and the second sample carrier 108B asynchronously between individual ones of the blocks 160.

[0054] Additional reference is made to FIG. 1D, which is an isometric view of a portion of the track 110 of FIG. 1C. In the embodiment of FIG. 1D, the first sample container 104A is received in the first sample carrier 108A and contains a first sample 162A that may be analyzed by one or more of the instruments 102 (FIG. 1A). FIG. 1 D also includes the second sample container 104B received in the second sample carrier 108B and contains a third sample 162B. The transport mechanisms 154 of FIG. 1D may be a single mechanism that enables the first sample carrier 108A and the second sample carrier 108B to be moved asynchronously into and out of the first block 160A and the second block 160B. For example, the transport mechanisms 154 may cause the first sample carrier 108A to wait within the first block 160A while moving the second sample carrier 108B from the second block 160B to the third block 160C. The position sensors 156 may be configured to identify the location of the first sample carrier 108A and the second sample carrier 108B on the track 110 and transmit position data to the routing program 126 (FIG. 1A). In some embodiments, the blocks 160 may be just slightly larger than the sample carriers 108. For example, the blocks 160 may be slightly larger than the footprint of either the first sample carrier 108A or the second sample carrier 108B.

[0055] Additional reference is made to FIG. 1E, which illustrates an embodiment of the first sample carrier 108A configured to be self-propelled. The first sample carrier 108A mayinclude a housing 168 in which a motor 170 and a receiver 172 may be located. The motor 170 may be coupled to wheels 174 extending from the housing 168. The receiver 172 may receive transport instructions from the sample carrier controller 128 indicating that the first sample carrier 108A is to move. In some embodiments, the instructions may include the velocity, acceleration, and / or direction that the first sample carrier 108A is to move. The receiver 172 may then activate the motor 170, which spins the wheels 174 and moves the first sample carrier 108A per the instructions. In some embodiments, coils or the like may be in the transport mechanisms 154 and may generate electric fields that provide power to the motor 170. Alternatively, power may be provided to the motor 170 to move the first sample carrier 108A by other methods and devices.

[0056] Reference is made to FIGS. 1 F and 1G, which illustrate an embodiment of the transport mechanisms 154 configured as linear motors. In the embodiment of FIG. 1F, the transport mechanisms 154 include coils 178 configured to generate magnetic fields in response to signals generated by the sample carrier controller 128 (FIG. 1A). The base 180 of the housing 168 (FIG. 1G) may be magnetized so that force may be applied to the base 180 as the magnetic fields generated by the coils 178 change. The force causes the first sample carrier 108A to move on the track 110.

[0057] During operation of the laboratory system 100, the routing program 126 may generate routing plans that are at least partially executed by the sample carrier controller 128 based on asynchronous movement of the sample carriers 108. As described above, asynchronous movement includes movement of the sample carriers 108 based on individual movement characteristics of the sample carriers 108. Reference is made to FIG. 2A and FIG. 2B to illustrate synchronous movement and asynchronous movement of the sample carriers 108. FIG. 2A illustrates sample carriers 1 , 2, and 3 located in certain blocks 202 on a track at a time t=0. FIG. 2B illustrates the sample carriers 1 , 2, and 3 after an incremental time t=1 , wherein the sample carriers 1 and 2 have synchronously moved to different ones of the blocks 202.

[0058] At the time t=0, a routing plan has been generated to move sample carrier 1 east from block A to block B and sample carrier 2 south from block B to block D. This routing may be performed by sample carrier 1 and sample carrier 2 moving synchronously at t=1 , which prevents sample carrier 1 and sample carrier 2 from colliding. In asynchronous movement, sample carrier 1 and sample carrier 2 may be independently moved, such as by instructions generated by the sample carrier controller 128. If sample carrier 2 has movement characteristics that do not enable it to move south before sample carrier 1 moves east, there is a possibility of a collision when sample carrier 1 moves east at t=1. The collision may be avoided by instructing sample carrier 2 to move faster or instructing sample carrier 1 to moveslower. The collision may also be avoided by instructing sample carrier 1 to wait until sample carrier 2 has moved. Any of these collision avoidance methods may be included in routing plans generated by routing program 126 for executing the asynchronous movements of sample carrier 1 and sample carrier 2 as described herein.

[0059] The laboratory system 100 and the methods disclosed herein provide routing plans that allow asynchronous movement of the sample carriers 108 in the presence of unknown or unforeseen sample carrier conflicts. The unknown or unforeseen sample carrier conflicts may exist in the original synchronous routing plans upon which routing plans generated by routing program 126 are based. The laboratory system 100 and methods disclosed herein may trigger re-planning processes that regenerate routing plans when the sample carrier conflicts are so great that an original routing plan may need to be modified to match the working state of the laboratory system 100. For example, in FIG. 2A and FIG. 2B, if the routing program 126 determines that sample carrier 2 cannot be moved from block B at or by t=1 , the routing program 126 may need to re-plan a new action for sample carrier 1 in view of the dependency of sample carrier 1 on the movement and / or movement characteristics of sample carrier 2.

[0060] In some embodiments, routes of sample carriers 108 with specific destinations are initially planned by the routing program 126 to move the sample carriers 108 synchronously. The routing plans may be converted to distributed commands that are configured to direct individual ones of the sample carriers 108 to move in specific routes. For example, the sample carrier controller 128 may generate instructions that are to be transmitted to individual ones of the sample carriers 108. The instructions may be executed by controllers that move individual ones of the sample carriers 108 asynchronously. The routing program 126 may ensure that the original synchronous routing plan is adhered to even though the routing plan may be executed by asynchronous movement of the sample carriers 108. In some embodiments, multi-agent path finding (MAPF) algorithms may be used by the routing program 126 to plan the routes of the sample carriers 108. In some embodiments, the routing program 126 may ensure that the synchronous properties of the routing plans are maintained so that collisions and other sample carrier conflicts are avoided. For example, sample carrier conflicts are avoided when every sample carrier follows a synchronous sequence of movements. However, if one sample carrier moves at a velocity that is different than the velocity of the other sample carriers, there are possibilities of sample carrier conflicts.

[0061] Additional reference is made to FIG. 3A, which is an example of a block diagram 300 illustrating the track 110 represented as a plurality of adjacent blocks 160. The block diagram 300 of FIG. 3A may be a simplified block representation of the track 110. Forexample, other block representations may include many more blocks 160 or fewer blocks 160. In some embodiments, the routing program 126 or another program may electronically represent the track 110 as the plurality of blocks 160. The routing program 126 then generates routes for each of the sample carriers 108 between adjacent ones of the blocks 160. For example, the routing program 126 may instruct the transport mechanisms 154 to move the sample carriers 108 to certain adjacent blocks when those adjacent blocks are vacant. The routing program 126 may generate a queue of block commands for each of the blocks 160 instructing individual ones of the blocks 160 to receive the sample carriers 108 synchronously from specific adjacent blocks and to discharge the sample carriers 108 to specific adjacent blocks in specific orders as described herein. One of the advantages of the block representation is that initial planning of movements of the sample carriers 108 becomes much simpler because only movements of the sample carriers 108 between the blocks 160 needs to be considered.

[0062] The embodiments herein describe moving the sample carriers 108 between adjacent blocks 160 (which also includes moving sample containers 104 carried by the sample carriers 108 between adjacent blocks). Each of the blocks 160 may have an associated movement constraint (indicated by arrows) that indicates in which direction the sample carriers 108 can move into and out of each of the blocks 160. By default, the movement constraints may be defined by the physical layout of the track 110. For example, a four-way intersection having four ports may have default movement constraints into and out of each of the four ports. The movement constraints may be physical constraints wherein portions of the track 110 corresponding to one or more of the blocks 160 may only enable the sample carriers 108 to move in specific directions. In other embodiments, the movement constraints may be changeable. For example, software, such as the routing program 126 and / or the sample carrier controller 128, may determine the directions of the movement constraints for each of the blocks 160. These directions, for example, may limit some of the blocks to having one-way (e.g., left to right) movement constraints.

[0063] Additional reference is made to FIG. 3B, which illustrates an enlarged view of the first block 160A, which, in some embodiments, may be identical to at least the blocks 160A, 160B, 160D, and 160E and blocks representing other straight segments of the track 110. The block 160A has a first port 301 A and a second port 301 B with a double-headed arrow shown between the first port 301 A and the second port 301 B. The double-headed arrow is indicative of the movement constraint of the first block 160A and indicates that the sample carriers 108 (and thus sample containers 104) are able to be received into and transported out of both the first port 300A and the second port 300B.

[0064] Referring again to FIG. 3A, a block 302 is a corner block corresponding to the second segment 144 of FIG. 1B. The block 302 is configured to change the direction of sample containers 104 between the x-direction and the y-direction. Additional reference is made to FIG. 3C, which illustrates an enlarged view of the block 302. The block 302 has a first port 302A and a second port 302B with a double-headed arrow shown between the first port 302A and the second port 302B. The double-headed arrow is indicative of the movement constraint of the block 302 and indicates that the sample carriers 108 (and thus the sample containers 104) may be received into and transported out of both the first port 302A and the second port 302B, which causes the sample carriers 108 to change direction between the x-direction and the y-direction.

[0065] Referring again to FIG. 3A, a block 304 is an intersection block corresponding to the third segment 146 of FIG. 1 B. The block 304 is configured to receive a sample carrier into a first port and transport the sample carrier out of one of two other ports. Additional reference is made to FIG. 3D, which illustrates an enlarged view of the block 304. The block 304 has a first port 304A, a second port 304B, and a third port 304C with arrows shown between the first port 304A, the second port 304B, and the third port 304C. The arrows are indicative of the movement constraints of the block 304, wherein the sample carriers 108 (and thus the sample containers 104) are able to be received into one port and transported out of one of the other ports. The sample carriers 108 are also able to be received into one of two ports and transported out of a third port.

[0066] A block 308 in FIG. 3A is an intersection block corresponding to the fourth segment 148 of FIG. 1B. The block 308 is configured similar to the block 304. In FIG. 3A, a block 310 is a corner block corresponding to the fifth segment 150 of FIG. 1 B and a block 312 is a corner block corresponding to the sixth segment 152 of FIG. 1B. The block 310 and the block 312 are configured similar to the block 302. The block 310 is a mirror of block 302 and the block 312 is a mirror of block 310.

[0067] The block 160H is a 4-way intersection that corresponds to the intersection segment 190 of FIG. 1A. The block 160H is configured to receive the sample carriers 108 into and transport the sample carriers 108 out of first, second, third, and fourth ports. Additional reference is made to FIG. 3E, which illustrates an enlarged view of the block 160H. The block 160H has a first port 306A, a second port 306B, a third port 306C, and a fourth port 306D that enable the sample carriers 108 to enter and exit all the ports. The routing program 126 may be configured to direct the sample carriers 108 to move into and out of the blocks 106 as described above.

[0068] Reference is now made to FIG. 4A, which illustrates certain ones of the blocks 160 that correspond to the segments 142 and 153 (FIG. 1 B) of the track 110 and will beused to illustrate examples of asynchronously moving the sample carriers 108 when a sample carrier conflict occurs. The blocks 160A-160J correspond to portions of the first segment 142 (FIG. 1B) and the seventh segment 153 in the track 110. In this example, the portion of the first segment 142 of the track 110 is configured to hold five of the sample carriers 108 and thus has five blocks 160A-160E. Further to the example, the portion of the seventh segment 153 of the track 110 is also configured to hold five of the sample carriers 108 and thus has the five blocks 160F-160J. In the example embodiment shown, each of the blocks 160A-160J is configured to hold a single one of the sample carriers 108 and movement of the sample carriers 108 may be initially planned synchronously from one block to an adjacent block when the adjacent block is vacant or as the adjacent block becomes vacant.

[0069] In a first scenario, the first sample carrier 108A is directed to move a first sample container 104A from a first location 400 (illustrated as a solid square) in the block 160C to a first destination 402 (illustrated as a dashed square) in the block 160F. An example of a first route may include a route (e.g., block 160C->block 160H->block 160G->block 160F) from the first location 400 to the first destination 402 or another other suitable route.Simultaneously, the second sample carrier 108B is directed to move a second sample container 104B from a second location 406 (illustrated as a solid circle) in the block 160G to a second destination 408 (illustrated as a dashed circle) in the block 1601. An example of a second route may include a route (e.g., block 160G->block 160H->block 1601) from the second location 406 to the second destination 408 or another other suitable route.

[0070] If the routes of the first sample carrier 108A and the second sample carrier 108B do not consider locations of each other and the movements are synchronous, the first sample carrier 108A and the second sample carrier 108B will collide at block 160H. In some synchronous routing plans, the first sample carrier 108A may wait one time increment while the second sample carrier 108B moves to block 160H. During the next time increment, the second sample carrier 108B may move to block 1601 while the first sample carrier moves to block 160H. Such a plan may operate correctly if both the first sample carrier 108A and the second sample carrier 108B execute their movement plans synchronously. This synchronous routing plan, however, is susceptible to failure if the first sample carrier 108A and the second sample carrier 108B are controlled independently and / or move asynchronously. For example, if the first sample carrier 108A executes instructions and moves twice as fast as the second sample carrier 108B, the sample carriers will collide in block 160H despite the original routing plan being free of collisions.

[0071] One method of overcoming sample carrier conflicts (e.g., collisions) when executing synchronous routing plans asynchronously according to one or moreembodiments is by incorporating dependencies. Dependencies include movements of a first sample carrier that are dependent on a location or movement of a second sample carrier. The dependencies may be generated using dependency graphs. Additional reference is made to FIG. 4B, which illustrates a dependency graph that avoids sample carrier conflicts in the sample container routing of FIG. 4A. With the dependency representation, the movement of the first sample carrier 108A to block 160H is shown to depend on the second sample carrier 108B completing its move to block 160H and then to block 1601. The first sample carrier 108A may then safely traverse block 160H. Sample carrier movements that do not have dependencies on other sample carrier movements advantageously can be executed asynchronously (e.g., at their own velocities) with no risk of collisions. For example, the second sample carrier 108B may proceed to block 160J and beyond asynchronously if there are no other sample containers that may impede or interfere with movement of the second sample carrier 108B.

[0072] In some embodiments, the routing program 126 may determine that the original routing plan is not feasible and may generate a new routing plan. For example, if the second sample carrier 108B cannot move to block 1601 (i.e., there is a constraint such as a sample spill or track defect), then there is no way for the first sample carrier 108A to reach the first destination 402. In these situations, the routing program 126 may generate new routing plans for one or both of the first sample carrier 108A and the second sample carrier 108B. In some embodiments, the new routing plan may utilize other areas of the track 110 to move the sample carriers to their respective destinations.

[0073] In some embodiments, the routing program 126 may attempt to minimize the number of dependencies in the routes. This enables each of the sample carriers 108 to travel the shortest paths or the shortest times to their destinations. It also enables the sample carriers 108 to move at their highest velocities because they will encounter only a minimal number of other sample carriers and / or sample carrier conflicts. In some embodiments, the routing program 126 may include timing cushions in the routing plans around the dependencies to ensure a safer execution of the routing plans. For example, the routing program 126 may generate instructions that direct the first sample carrier 108A to wait two timesteps at block 160C instead of one timestep before moving to block 160H even though the ideal (synchronous) routing plan has block 160H open after one timestep. In some embodiments, the dependency may be for the second sample carrier 108B to move to the block 1601.

[0074] FIG. 5 illustrates a flowchart of a method 500 of operating the laboratory system 100 with asynchronous sample carriers 108 that may avoid sample carrier conflicts. The method 500 commences at block 502 where sample containers 104 and testing instructionsare received at the laboratory system 100. The sample containers 104 may contain biological samples that are to be tested by the instruments 102 and may be received in the sample handler 102C. The sample containers 104 may be placed into independently- controlled sample carriers 108 to be moved on the track 110 per instructions generated by the sample carrier controller 128. In some embodiments, the testing instructions may be transmitted from a hospital information system (not shown) to the computer 120. The testing instructions may include the tests to be performed on each of the biological samples.

[0075] Processing proceeds to block 504 where the state of the laboratory system 100 may be updated. This updated information may be used by the routing program 126 to plan routes for the sample carriers 108. The state of the laboratory system 100 may include the present locations of the sample carriers 108, their destinations, operating status of instruments 102 (e.g., whether online or offline), track status (e.g., whether any track sections are closed because of sample spills, malfunctioning carriers stuck thereon, and / or track switch malfunctions or other track defects) or the like. The present locations of the sample carriers may be determined by the position sensors 156 (FIG. 1 B) or the sample carriers themselves transmitting back to the computer 120, for example. In some embodiments, the layout of the track 110 may be input to the routing program 126. In some embodiments, the routing program 126 may receive a block representation of the track 110 (FIG. 3A) or the routing program 126 may generate the block representation of the track 110.

[0076] In block 506, the routing program 126 generates routes (e.g., a routing plan) to move at least a plurality of the sample carriers 108 simultaneously (including, e.g., the sample carriers 108 receiving the most recently-received sample containers 104 at the sample handler 102C). In some embodiments, the routing program 126 may initially generate a list of discrete time steps and associated sample carrier movements that constitute synchronous movements of the sample carriers 108. Each sample carrier time step may be based at least in part on the positions of all the sample carriers 108. From one time step to the next time step, the routing plan may direct each of the sample carriers 108 to stay in place (e.g., wait) in the present track block or move to an adjacent track block. In some embodiments, a track block may never be occupied by more than one of the sample carriers 108. After the routing plan is generated, the routing plan may be transformed into a queue of block commands for each of the track blocks 160. A block command may include the time steps, whether a sample carrier is to enter or exit a block, a sample carrier identification, and a direction of movement of the sample carrier. If it is necessary to have a sample carrier wait in a block for a certain amount of time (or until a certain time) the block command may include a wait command. For example, referring to FIG. 4A, the routing program 126 may generate the following time step movements for sample carriers 108A and 108B:

[0077] Carrier 108A: Block 160C -> Wait 160C -> Block 160H -> Block 160G -> Block 160F

[0078] Carrier 108B: Block 160G -> Block 160H -> Block 1601

[0079] At this point in the route planning, each of the blocks 160 has a series of block commands that depend on the order that the sample carriers 108 arrive at the blocks 160 and / or depart from the blocks 160. With synchronous movement, as long as each queue of block commands is performed in order, the routing plan will be executed correctly. Specifically, each of the sample carriers 108 will reach their respective destinations without colliding and in the correct order. However, as described above, the routing plan may not work correctly when the sample carriers 108 move asynchronously. For example, if a possible conflict exists between the first and second sample carriers and the first sample carrier moves faster or slower than the second sample carrier, a single time step wait command, which may work with synchronous carrier movements, may result in a collision between the first and second carriers.

[0080] To address the above potential carrier conflicts, the routing program 126 in block 508 may identify sample carrier dependencies in the routes generated in block 506. The sample carrier dependencies may include situations where a first sample carrier (e.g., first sample carrier 108A) cannot move into a block 160 until a second sample carrier (e.g., second sample carrier 108B) moves out of that block 160. For example, the routing program 126 may identify the dependency created by the planned routes of sample carriers 108A and 108B above with respect to blocks 160H and 160G. That is, the routing program 126 is operative to recognize that sample carrier 108A cannot move into block 160H and then block 160G until sample carrier 108B moves out of block 160G and through block 160H to block 1601. This dependency may be represented by a “dependency graph,” as shown in FIG. 4B. Such identified dependencies may be incorporated into the routing plans. For example, a dependency may be incorporated into the routing plan of first sample carrier 108A wherein movement of the first sample carrier 108A cannot occur until the second sample carrier 108B moves out of block 160H. A dependency may also include movement of a first sample carrier on a first track segment onto another track segment to allow a second sample carrier to pass by on the first track segment.

[0081] In block 510, the planned routes are executed. That is, routing program 126 communicates the routing plans to sample carrier controller 128, which in response issues movement instructions to the sample carriers 108. Note that in addition to carrier destinations, planned routes may also include time windows or time constraints wherein a planned route or portions thereof (hereinafter referred to collectively as “a planned route’ or “planned routes”) may be expected or required to complete within a certain time window orperiod of time. In some embodiments method 500 and the routing program 126 may be continuously / continually executed and performed as new sample containers 104 arrive at the laboratory system 100 and are loaded into the sample handler 102C and / or as the state of laboratory system 100 changes. During execution of the routing plans, position sensors 156 and sample carriers 108 may provide real-time feedback to computer 120 (and routing program 126) regarding sample carrier positions, distance between sample carriers, sample carrier movement characteristics (e.g., velocity), etc.

[0082] In decision block 512, a determination is made as to whether all the sample carrier planned routes have executed successfully. That is, method 500 determines at decision block 512 whether the sample carrier planned routes executed successfully within any time windows or time constraints associated with the planned routes. If the result at decision block 516 is YES (meaning all planned routes executed successfully), processing proceeds to END block 514, which terminates the present route planning. As described above, in some embodiments, route planning is a continual / continuous process, so processing may instead return to block 502 from END block 514 to repeat method 500 with one or more recently-received sample containers 104 to be loaded onto respective sample carriers 108 at sample handler 102C.

[0083] If the determination at decision block 512 is NO (meaning one or more planned routes exceeded or are likely to exceed their respective time window or time constraint (as determined by computer 120 in response to communications received from position sensors 156 and / or sample carriers 108) and / or one or more planned routes were not able to complete because of a system state condition (e.g., an unavailable instrument 102, a defective sample carrier 108, and / or a track 110 defect as reported to computer 120 by instruments 102, track sensors, position sensors 156, and / or sample carriers 108 during execution of the planned routes), processing proceeds to decision block 516.

[0084] At decision block 516, a determination is made as to whether replanning of one or more of the unsuccessful planned routes is required. If the determination at decision block 516 is YES, processing returns to block 504 to replan the unsuccessful routes (and any other sample carrier routes affected by the unsuccessful routes). Where possible, in some embodiments, method 500 via routing program 126 may dynamically replan one or more planned routes (which may include modifying or adding one or more movement dependencies) as the one or more planned routes are executing. That is, a remaining (unexecuted) portion of a planned route and / or operative or pending movement dependency may be modified by the replanning.

[0085] Replanning may be required if a planned route was not able to successfully complete because of a system state condition. For example, if an instrument in the plannedroute suddenly goes offline or a track switch malfunctions by failing to switch as needed, method 500 may proceed to block 504 to replan the unsuccessful route and any other routes affected thereby.

[0086] In another example, a planned route may not be able to complete if a sample carrier 108 malfunctions and does not move or moves too slowly as reported to computer 120 by position sensors 156 and / or the malfunctioning sample carrier 108. In such a case, manual intervention may be required to remove and / or replace the malfunctioning sample carrier 108 and method 500 may proceed to block 504 to replan its route and any other routes affected thereby.

[0087] In still another example, replanning may be required if a planned route with an associated time constraint is determined by computer 120 to not likely meet that time constraint based on sample carrier position feedback. For example, assume a sample carrier 108 is required to visit four instruments 102 within a total time period T, and position feedback indicates that after visiting the first instrument 102, time period T is likely to be exceeded. In that case, method 500 may proceed to block 504 to replan the portion of the route to the remaining three instruments (and replan all other carrier routes affected thereby) by giving that sample carrier 108 the highest priority over all other sample carriers encountered along the way to the three remaining instruments 102 to ensure that the time period T is met.

[0088] Replanning may also be required if sample carrier position monitoring indicates that a movement dependency cannot be maintained. For example, referring to FIG. 6, assume first and second sample carriers 108C and 108D are initially separated by block 160F (as shown). Each of first and second sample carriers 108C and 108D has a planned route moving in the same direction D61 , and the second sample carrier 108D has a movement dependency of maintaining a one-track block distance between it and the first sample carrier 108C. However, position monitoring indicates that the second sample carrier 108D is moving faster than the first sample carrier 108C and thus the movement dependency of second sample carrier 108D cannot be maintained. In such a case, method 500 may proceed to block 504 to replan the route of the first sample carrier 108C by, e.g., adding a movement dependency the first sample carrier 108C to increase its speed (if possible) such that the second sample carrier 108D will not overtake and collide with the first sample carrier 108C. Additionally or alternatively, the route of the second sample carrier 108D may be replanned by adding / modifying its movement dependency to, e.g., decrease its speed such that the second sample carrier 108D will not overtake and collide with the first sample carrier 108C, wait a predetermined amount of time to allow the first sample carrier 108C to increase its distance from the second sample carrier 108D, and / or maintain agreater track block distance between it and the first sample carrier 108C. Another route replanning option may be to direct the first sample carrier 108C to move out of the path of the second sample carrier 108D to let the second sample carrier 108D pass the first sample carrier 108C. For example, the first sample carrier 108C may be temporarily diverted to the block 160C. This alternative dependency may be added by method 500 if, e.g., the first sample carrier 108C had a less restrictive time constraint or a lower priority than the second sample carrier 108D. Other replanning options for avoiding a collision between the first and second sample carriers 108C and 108D each moving in the direction D1 may be possible.

[0089] On the other hand, replanning an unsuccessful route may not be required if a planned route exceeded an associated time window, but its applicable movement dependencies are still operative (i.e., valid or in force). For example, referring to FIG. 4A and the following planned routes for sample carriers 108A and 108B: tO t1 t2 t3

[0090] Carrier 108A: Block 160C -> Wait 160C -> Block 160H -> Block 160G

[0091] Carrier 108B: Block 160G -> Block 160H -> Block 1601 -> Block 160J

[0092] Sample carrier 108A has a movement dependency (identified at method 500, block 508) wherein sample carrier 108A cannot move until sample carrier 108B moves into and out of track block 160H. Assuming synchronous movement of sample carriers 108A and 108B, sample carrier 108A is expected to arrive at track block 160H at timestep t2 after waiting one timestep at t1 . If, however, position monitoring indicates that sample carrier 108B is moving slower than expected and sample carrier 108A has not arrived at track block 160H at timestep t2, method 500 may indicate at decision block 512 that the planned route of sample carrier 108A did not successfully complete. At decision block 516, method 500 may determine that replanning is not required because the dependency of sample carrier 108A not moving until sample carrier 108B moves into and out of track block 160H is still operative and thus there is no likelihood of a collision between sample containers 108A and 108B at track block 160H. In this case, the determination at decision block 516 is NO (meaning replanning of the routes is not required) and method 500 may return to block 510 to allow continued execution of the planned routes.

[0093] In sum, should the sample carrier position monitoring and other feedback indicate potential problems (e.g., unexpected variations in carrier movement characteristics, likely collisions, unacceptable delays, etc.) affecting one or more of the planned routes during execution at block 510, method 500 may proceed to decision blocks 512 and 516 to determine whether routing program 126 needs to replan one or more the planned routes or any unexecuted portions thereof including revising or adding movement dependencies to avoid any sample carrier collisions and / or meet any sample carrier time constraints. Thereplanned routing plans may be forwarded to sample carrier controller 128, which may then transmit appropriate routing instructions to the affected sample carriers.

[0094] As described above, in some embodiments, route planning for all or some of the sample carriers 108 in the laboratory system 100 may be generated or updated in a continual or continuous fashion. For example, routing plans may be generated or updated after a predetermined number of timesteps. In other embodiments, routing plans may be generated or revised whenever one or more new sample containers are received into the laboratory system 100. In other embodiments, routing plans may be generated or revised whenever a change occurs in the laboratory system 100 that requires the sample carriers 108 (carrying sample containers 104) to visit different instruments, such as whenever an instrument is taken offline for maintenance, malfunction, or depleted supplies.

[0095] Referring again to FIG. 3A, although the track blocks 160 have been described as being square or rectangular, other block shapes / types may be used. For example, pentagonal-shaped blocks may be used to represent intersection segments having five ports. The movements of sample carriers 108 and sample containers 104 have been described as being in a two-dimensional plane. Thus, the blocks 160 have also been described as being two-dimensional. In other embodiments, movement of the sample containers 104 and / or the sample carriers 108 may be in three dimensions, such X, Y, and Z, wherein the Z dimension is normal to the track 110. In such embodiments, one or more of the blocks 160 may be three-dimensional and represented as, e.g., cube-shaped.

[0096] Reference is made to FIG. 7, which illustrates a three-dimensional block diagram 700 of a portion of a track (not separately shown) that may move sample carriers 108 (FIG. 1A) and / or sample carriers 108 in three dimensions. In the embodiment of FIG. 7, the sample carriers 108 are configured to move in an x-direction, a y-direction, and a z-direction to adjacent vacant blocks. A block 702 has movement constraints in the x-direction and the y-direction. A block 704 has movement constraints in the y-direction and the z-direction.Other blocks may have other movement constraints. The routing program 126 may route the sample carriers 108 between adjacent blocks or cubes as described above.

[0097] Reference is now made to FIG. 8, which illustrates a flowchart of a method 800 of operating a diagnostic laboratory system (e.g., laboratory system 100). The method 800 includes in block 802, providing a first sample carrier (e.g., first sample carrier 108A) movable on a track (e.g., track 110) in the diagnostic laboratory system, wherein the first sample carrier has at least one first movement characteristic and the track extends between a plurality of instruments (e.g., instruments 102) and supports asynchronous movement of sample carriers.

[0098] The method 800 includes in block 804, providing a second sample carrier (e.g., second sample carrier 108B) movable on the track, wherein the second sample carrier has at least one second movement characteristic and the first and second sample carriers are movable independently of each other. The at least one first and second movement characteristics may each include velocity or acceleration of the respective sample carrier or friction between the respective sample carrier and the track.

[0099] The method 800 includes in block 806, identifying a first location (e.g., first location 400) of the first sample carrier and identifying a second location (e.g., second location 406) of the second sample carrier. The method 800 includes in block 808, generating a first route to move the first sample carrier from the first location to a first destination (e.g., first destination 402) which, in some embodiments, may be based at least in part on the at least one first movement characteristic. The route from the first location 400 to the first destination 402 in FIG. 4A is an example of a first route, although other first routes may be employed. The method 800 includes in block 810, generating a second route to move the second sample carrier from the second location to a second destination (e.g., second destination 408) which, in some embodiments, may be based at least in part on the at least one second movement characteristic. The route from the second location 406 to the second destination 408 in FIG. 4A is an example of a second route, although other second routes may be employed.

[0100] The method 800 includes in block 812, determining if a sample carrier conflict exists between the first and second routes. A sample carrier conflict may be, for example, a potential collision between the first and second sample carriers. The method 800 includes in block 814, identifying at least one dependency in the first route or the second route in response to the determining that a sample carrier conflict exists, wherein the at least one dependency makes movement of the first sample carrier dependent on movement of the second sample carrier (e.g., so the first and second sample carriers cannot collide). If the conflict cannot be cured by identifying at least one dependency, then the routing plan may be regenerated.

[0101] Reference is now made to FIG. 9, which illustrates a flowchart of a method 900 of moving a first sample carrier (e.g., first sample carrier 108A) and a second sample carrier (e.g., second sample carrier 108B) in a diagnostic laboratory system (e.g., laboratory system 100). The method 900 includes in block 902, providing a track (e.g, track 110) in the diagnostic laboratory system, wherein the track extends between a plurality of instruments (e.g., instruments 102). The track supports asynchronous movement of the sample carriers.

[0102] The method 900 includes in block 904, providing a first sample carrier (e.g., first sample carrier 108A) movable on the track, wherein the first sample carrier is self-propelledand is movable at a first velocity. The method 900 includes in block 906, providing a second sample carrier (e.g., second sample carrier 108B) movable on the track, wherein the second sample carrier is self-propelled and is movable at a second velocity, and wherein the first velocity is different than the second velocity. In some embodiments, the velocities of the sample carriers may be variable and set by the sample carrier controller 128.

[0103] The method 900 includes in block 908, identifying a first location (e.g., first location 400) of the first sample carrier and identifying a second location (e.g., second location 406) of the second sample carrier. The method 900 includes in block 910, generating a first route to move the first sample carrier from the first location to a first destination (e.g., first destination 402) based at least in part on the first velocity and generating a second route to move the second sample carrier from the second location to a second destination (e.g., second destination 408) based at least in part on the second velocity. The route from the first location 400 to the first destination 402 in FIG. 4A is an example of a first route, although other first routes may be employed. The route from the second location 406 to the second destination 408 in FIG. 4A is an example of a second route, although other second routes may be employed.

[0104] The method 900 includes in block 912, determining if a sample carrier conflict exists between the first route and the second route. A sample carrier conflict may be determined where the first and second sample carriers have to pass one another or yield to one another at certain times or locations on the track during execution of the first and second routes. The method 900 includes in block 914, identifying at least one dependency in response to the determining that a sample carrier conflict exists, wherein the at least one dependency comprises directing the first sample carrier to wait while directing the second sample carrier to move. Alternatively, in some embodiments, the first sample carrier may instead be directed to a portion of the track that is out of the way of the route of the second sample carrier. The method 900 includes in block 916, executing the first route and the second route.

[0105] While the disclosure is susceptible to various modifications and alternative forms, specific method and apparatus embodiments have been shown by way of example in the drawings and are described in detail herein. It should be understood, however, that the particular methods and apparatus disclosed herein are not intended to limit the disclosure.NON-LIMITING ILLUSTRATIVE EMBODIMENTS

[0106] Illustrative embodiment 1. A method of operating a diagnostic laboratory system, the method comprising: providing a first sample carrier movable on a track in the diagnostic laboratory system, wherein the first sample carrier has at least one first movement characteristic and the track extends between a plurality of instruments; providinga second sample carrier movable on the track, wherein the second sample carrier has at least one second movement characteristic and the first and second sample carriers are movable independently of each other; identifying a first location of the first sample carrier and a second location of the second sample carrier; generating a first route to move the first sample carrier from the first location to a first destination; generating a second route to move the second sample carrier from the second location to a second destination; determining if a sample carrier conflict exists between the first and second routes; and identifying at least one dependency in the first route or the second route in response to the determining indicating that a sample carrier conflict exists, wherein the at least one dependency makes movement of the first sample carrier dependent on movement of the second sample carrier.

[0107] Illustrative embodiment 2. The method according to the preceding illustrative embodiment, wherein the determining if a sample carrier conflict exists comprises determining whether the first and second sample carriers have to pass one another or yield to one another at certain times or locations on the track during execution of the first and second routes.

[0108] Illustrative embodiment 3. The method according to one of the preceding illustrative embodiments, wherein the identifying the at least one dependency comprises directing the first sample carrier to wait while directing the second sample carrier to move.

[0109] Illustrative embodiment 4. The method according to one of the preceding illustrative embodiments, further comprising executing the first and second routes and monitoring the first and second carrier positions to determine if the first and second routes have completed successfully.

[0110] Illustrative embodiment 5. The method according to one of the preceding illustrative embodiments, further comprising, in response to the monitoring indicating that the first or second route did not complete successfully, determining whether the first or second route needs to be replanned.

[0111] Illustrative embodiment 6. The method according to one of the preceding illustrative embodiments, further comprising determining that the first or second route does not need to be replanned in response to the monitoring indicating that the first or second sample carrier is moving slower than expected and the at least one dependency is still operative.

[0112] Illustrative embodiment 7. The method according to one of the preceding illustrative embodiments, further comprising determining that the first or second route needs to be replanned in response to the monitoring indicating that the first or second sample carrier is moving faster than expected and the at least one dependency cannot be maintained.

[0113] Illustrative embodiment 8. The method according to one of the preceding illustrative embodiments, further comprising replanning the first or second route to include directing the first or second sample carrier that is moving faster than expected to decrease velocity.

[0114] Illustrative embodiment 9. The method according to one of the preceding illustrative embodiments, further comprising replanning the first or second route to include a revised dependency of an increased wait time for one of the first or second carriers.

[0115] Illustrative embodiment 10. The method according to one of the preceding illustrative embodiments, further comprising determining that the first or second route needs to be replanned in response to the monitoring indicating that the first or second sample carrier has malfunctioned.

[0116] Illustrative embodiment 11 . The method according to one of the preceding illustrative embodiments, wherein the at least one first movement characteristic or the at least one second movement characteristic is velocity, acceleration, or track friction.

[0117] Illustrative embodiment 12. The method according to one of the preceding illustrative embodiments, wherein the first sample carrier and the second sample carrier are controlled independently by a sample carrier controller.

[0118] Illustrative embodiment 13. A diagnostic laboratory system for analyzing a biological sample, comprising: a plurality of instruments; a track located in the diagnostic laboratory system, wherein the track extends between the plurality of instruments; a first sample carrier movable on the track, wherein the first sample carrier has at least one first movement characteristic; a second sample carrier movable on the track, wherein the second sample carrier has at least one second movement characteristic and the first and second sample carriers are movable independently of each other; a computer having instructions executable to: identify a first location of the first sample carrier; identify a second location of the second sample carrier; generate a first route to move the first sample carrier from the first location to a first destination; generate a second route to move the second sample carrier from the second location to a second destination; determine if a sample carrier conflict exists between the first and second routes; identify at least one dependency in the first route or the second route in response to determining that a sample carrier conflict exists, wherein the at least one dependency makes movement of the first sample carrier dependent on movement of the second sample carrier; execute the first and second routes and monitor positions of the first and second sample carriers; and in response to monitoring that the first or second route did not complete successfully, determine whether the first or second route needs to be replanned.

[0119] Illustrative embodiment 14. The diagnostic laboratory system according to the preceding illustrative embodiment, wherein a sample carrier conflict exists where the first and second sample carriers have to pass one another or yield to one another at certain times or locations on the track during execution of the first and second routes.

[0120] Illustrative embodiment 15. The diagnostic laboratory system according to one of the preceding illustrative embodiments, wherein the first or second route is determined to have not completely successfully when the first sample carrier has not moved after a predetermined period of time indicated in the at least one dependency.

[0121] Illustrative embodiment 16. The diagnostic laboratory system according to one of the preceding illustrative embodiments, wherein the first and second routes are determined to have completely successfully when the first and second sample carriers arrive respectively at the first and second destinations within a predetermined period of time indicated in the at least one dependency.

[0122] Illustrative embodiment 17. The diagnostic laboratory system according to one of the preceding illustrative embodiments, wherein the at least one first movement characteristic or the at least one second movement characteristic is friction between the track and the first sample carrier or the second sample carrier, velocity, or acceleration.

[0123] Illustrative embodiment 18. The diagnostic laboratory system according to one of the preceding illustrative embodiments, wherein at least one of the first and second sample carriers is self-propelled.

[0124] Illustrative embodiment 19. The diagnostic laboratory system according to one of the preceding illustrative embodiments, wherein the computer determines repeatedly whether a sample carrier conflict exists in each of the first and the second routes as a state of the diagnostic laboratory system changes.

[0125] Illustrative embodiment 20. A method of moving a first sample carrier and a second sample carrier in a diagnostic laboratory system, the method comprising: providing a track in the diagnostic laboratory system, wherein the track extends between a plurality of instruments; providing a first sample carrier movable on the track, wherein the first sample carrier is self-propelled and is movable at a first velocity; providing a second sample carrier movable on the track, wherein the second sample carrier is self-propelled and is movable at a second velocity, and wherein the first velocity is different than the second velocity; identifying a first location of the first sample carrier; identifying a second location of the second sample carrier; generating a first route to move the first sample carrier from the first location to a first destination based at least in part on the first velocity; generating a second route to move the second sample carrier from the second location to a second destinationbased at least in part on the second velocity; determining if a sample carrier conflict exists between the first route and the second route; identifying at least one dependency in response to the determining that a sample carrier conflict exists, wherein the at least one dependency comprises directing the first sample carrier to wait while directing the second sample carrier to move; and executing the first and second routes.

Claims

WHAT IS CLAIMED IS:

1. A method of operating a diagnostic laboratory system, the method comprising: providing a first sample carrier movable on a track in the diagnostic laboratory system, wherein the first sample carrier has at least one first movement characteristic and the track extends between a plurality of instruments; providing a second sample carrier movable on the track, wherein the second sample carrier has at least one second movement characteristic and the first and second sample carriers are movable independently of each other; identifying a first location of the first sample carrier and a second location of the second sample carrier; generating a first route to move the first sample carrier from the first location to a first destination; generating a second route to move the second sample carrier from the second location to a second destination; determining if a sample carrier conflict exists between the first and second routes; and identifying at least one dependency in the first route or the second route in response to the determining indicating that a sample carrier conflict exists, wherein the at least one dependency makes movement of the first sample carrier dependent on movement of the second sample carrier.

2. The method of claim 1 , wherein the determining if a sample carrier conflict exists comprises determining whether the first and second sample carriers have to pass one another or yield to one another at certain times or locations on the track during execution of the first and second routes.

3. The method of claim 1 , wherein the identifying the at least one dependency comprises directing the first sample carrier to wait while directing the second sample carrier to move.

4. The method of claim 1 , further comprising executing the first and second routes and monitoring the first and second carrier positions to determine if the first and second routes have completed successfully.

5. The method of claim 4, further comprising, in response to the monitoring indicating that the first or second route did not complete successfully, determining whether the first or second route needs to be replanned.

6. The method of claim 5, further comprising determining that the first or second route does not need to be replanned in response to the monitoring indicating that the first or second sample carrier is moving slower than expected and the at least one dependency is still operative.

7. The method of claim 5, further comprising determining that the first or second route needs to be replanned in response to the monitoring indicating that the first or second sample carrier is moving faster than expected and the at least one dependency cannot be maintained.

8. The method of claim 7, further comprising replanning the first or second route to include directing the first or second sample carrier that is moving faster than expected to decrease velocity.

9. The method of claim 7, further comprising replanning the first or second route to include a revised dependency of an increased wait time for one of the first or second carriers.

10. The method of claim 5, further comprising determining that the first or second route needs to be replanned in response to the monitoring indicating that the first or second sample carrier has malfunctioned.11 . The method of claim 1 , wherein the at least one first movement characteristic or the at least one second movement characteristic is velocity, acceleration, or track friction.

12. The method of claim 1 , wherein the first sample carrier and the second sample carrier are controlled independently by a sample carrier controller.

13. A diagnostic laboratory system for analyzing a biological sample, comprising: a plurality of instruments; a track located in the diagnostic laboratory system, wherein the track extends between the plurality of instruments;a first sample carrier movable on the track, wherein the first sample carrier has at least one first movement characteristic; a second sample carrier movable on the track, wherein the second sample carrier has at least one second movement characteristic and the first and second sample carriers are movable independently of each other; a computer having instructions executable to: identify a first location of the first sample carrier; identify a second location of the second sample carrier; generate a first route to move the first sample carrier from the first location to a first destination; generate a second route to move the second sample carrier from the second location to a second destination; determine if a sample carrier conflict exists between the first and second routes; identify at least one dependency in the first route or the second route in response to determining that a sample carrier conflict exists, wherein the at least one dependency makes movement of the first sample carrier dependent on movement of the second sample carrier; execute the first and second routes and monitor positions of the first and second sample carriers; and in response to monitoring that the first or second route did not complete successfully, determine whether the first or second route needs to be replanned.

14. The diagnostic laboratory system of claim 13, wherein a sample carrier conflict exists where the first and second sample carriers have to pass one another or yield to one another at certain times or locations on the track during execution of the first and second routes.

15. The diagnostic laboratory system of claim 13, wherein the first or second route is determined to have not completely successfully when the first sample carrier has not moved after a predetermined period of time indicated in the at least one dependency.

16. The diagnostic laboratory system of claim 13, wherein the first and second routes are determined to have completely successfully when the first and second sample carriers arrive respectively at the first and second destinations within a predetermined period of time indicated in the at least one dependency.

17. The diagnostic laboratory system of claim 13, wherein the at least one first movement characteristic or the at least one second movement characteristic is friction between the track and the first sample carrier or the second sample carrier, velocity, or acceleration.

18. The diagnostic laboratory system of claim 13, wherein at least one of the first and second sample carriers is self-propelled.

19. The diagnostic laboratory system of claim 13, wherein the computer determines repeatedly whether a sample carrier conflict exists in each of the first and the second routes as a state of the diagnostic laboratory system changes.

20. A method of moving a first sample carrier and a second sample carrier in a diagnostic laboratory system, the method comprising: providing a track in the diagnostic laboratory system, wherein the track extends between a plurality of instruments; providing a first sample carrier movable on the track, wherein the first sample carrier is self-propelled and is movable at a first velocity; providing a second sample carrier movable on the track, wherein the second sample carrier is self-propelled and is movable at a second velocity, and wherein the first velocity is different than the second velocity; identifying a first location of the first sample carrier; identifying a second location of the second sample carrier; generating a first route to move the first sample carrier from the first location to a first destination based at least in part on the first velocity; generating a second route to move the second sample carrier from the second location to a second destination based at least in part on the second velocity; determining if a sample carrier conflict exists between the first route and the second route; identifying at least one dependency in response to the determining that a sample carrier conflict exists, wherein the at least one dependency comprises directing the first sample carrier to wait while directing the second sample carrier to move; and executing the first and second routes.

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