Extensible vertically-efficient laboratory automation system

Abstract

Various rail systems are provided for laboratory automation. An example rail system includes a first carriage structured to move along a first rail. The rail system also includes a second carriage structured to move along a second rail. The rail system further includes a third rail connected to the first carriage at a first end of the third rail and the second carriage at a second end of the third rail. At least one of the first carriage or the second carriage is connected to the third rail via an angular compliance mechanism. The angular compliance mechanism allows the at least one of the first carriage or the second carriage to rotate relative to the third rail.

Description

EXTENSIBLE VERTIC ALLY-EFFICIENT LABORATORY AUTOMATION SYSTEMFIELD

[0001] An example embodiment relates generally to laboratory automation and more particularly, to creating a laboratory automation system that is easily extendable.BACKGROUND

[0002] Most laboratory automation systems are comprised of a delicate arrangement of tables, rails, and robotic arms with gripping appendages to transport labware, plates, consumables, and / or the like. Such complex and delicate setups are difficult to deploy, often taking months to dry fit at a factory and then again to install at a customer site. Additionally, the larger the system, the more complex the retrieval functionality. As such, there exists a need for a laboratory automation system that improves the time required to fabricate, construct, and modify the system.SUMMARY

[0003] The following paragraphs present a summary of various embodiments of the present disclosure and are merely examples of potential embodiments. As such, the summary is not meant to limit the subject matter or variations of various embodiments discussed herein.

[0004] In some aspects, the techniques described herein relate to an automated rail system, the system including: a first carriage structured to move along a first rail; a second carriage structured to move along a second rail; and a third rail connected to the first carriage at a first end of the third rail and the second carriage at a second end of the third rail, wherein at least one of the first carriage or the second carriage is connected to the third rail via an angular compliance mechanism, wherein the angular compliance mechanism allows the at least one of the first carriage or the second carriage to rotate relative to the third rail.

[0005] In some aspects, the techniques described herein relate to a system, further including an arm mechanism attached to the third rail, wherein the arm mechanism is moveable along the third rail between the first end and the second end.

[0006] In some aspects, the techniques described herein relate to a system, wherein the arm mechanism is extendable along an axis perpendicular to an axis along the third rail between the first end and the second end.

[0007] In some aspects, the techniques described herein relate to a system, wherein the first rail and the second rail are attached to a shelf.

[0008] In some aspects, the techniques described herein relate to a system, wherein the first carriage includes a position tracking mechanism, wherein the position tracking mechanism engages one or more tracking markers.

[0009] In some aspects, the techniques described herein relate to a system, wherein the one or more tracking markers are barcodes.

[0010] In some aspects, the techniques described herein relate to a system, wherein the first carriage and the second carriage are independently moved.

[0011] In some aspects, the techniques described herein relate to a system, further including a sensor, wherein the sensor determines that at least one of the first carriage or the third rail moves relative to the second carriage.

[0012] In some aspects, the techniques described herein relate to a system, wherein upon a change in a sensor reading of the sensor, the second carriage is moved along the second rail.

[0013] In some aspects, the techniques described herein relate to a system, wherein the first carriage and the second carriage are each connected to the third rail via an angular compliance mechanism.

[0014] In some aspects, the techniques described herein relate to a method of manufacturing an automated rail system, the method including: providing a first carriage structured to move along a first rail; providing a second carriage structured to move along a second rail; and connecting a third rail to the first carriage at a first end of the third rail and the second carriage at a second end of the third rail, wherein at least one of the first carriage or the second carriage is connected to thethird rail via an angular compliance mechanism, wherein the angular compliance mechanism allows the at least one of the first carriage or the second carriage to rotate relative to the third rail.

[0015] In some aspects, the techniques described herein relate to a method, further including attaching an arm mechanism to the third rail, wherein the arm mechanism is moveable along the third rail between the first end and the second end.

[0016] In some aspects, the techniques described herein relate to a method, wherein the arm mechanism is extendable along an axis perpendicular to an axis along the third rail between the first end and the second end.

[0017] In some aspects, the techniques described herein relate to a method, wherein the first rail and the second rail are attached to a shelf.

[0018] In some aspects, the techniques described herein relate to a method, wherein the first carriage includes a position tracking mechanism, wherein the position tracking mechanism engages one or more tracking markers.

[0019] In some aspects, the techniques described herein relate to a method, wherein the one or more tracking markers are barcodes.

[0020] In some aspects, the techniques described herein relate to a method, wherein the first carriage and the second carriage are independently moved.

[0021] In some aspects, the techniques described herein relate to a method, further including providing a sensor, wherein the sensor determines that at least one of the first carriage or the third rail moves relative to the second carriage.

[0022] In some aspects, the techniques described herein relate to a method, wherein upon a change in a sensor reading of the sensor, the second carriage is moved along the second rail.

[0023] In some aspects, the techniques described herein relate to a method, wherein the first carriage and the second carriage are each connected to the third rail via an angular compliance mechanism.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Many aspects of the present disclosure will be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, with emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. It should be recognized that these implementations and embodiments are merely illustrative of the principles of the present disclosure. Therefore, in the drawings:

[0025] FIG. 1 illustrates an example rail system installed on a shelf, in accordance with various embodiments of the present disclosure;

[0026] FIG. 2 illustrates the rail of a rail system being attached to a shelf, in accordance with various embodiments of the present disclosure;

[0027] FIG. 3 illustrates an upper carriage attachable to the rail of a rail system, in accordance with various embodiments of the present disclosure;

[0028] FIG. 4 illustrates a lower carriage attachable to the rail of a rail system, in accordance with various embodiments of the present disclosure;

[0029] FIG. 5 illustrates the rail system being used in an instance in which a first rail and a second rail are not parallel, in accordance with various embodiments of the present disclosure;

[0030] FIG. 6 illustrates the rail system being used with a charging rail to charge at least one of the upper carriage or the lower carriage, in accordance with various embodiments of the present disclosure;

[0031] FIG. 7 is a flowchart of an example method of providing the rail system, in accordance with various embodiments of the present disclosure; and

[0032] FIG. 8 illustrates an example first rail with tracking markers, in accordance with various embodiments of the present disclosure.DETAILED DESCRIPTION

[0033] The presently disclosed subject matter now will be described more fully hereinafterwith reference to the accompanying drawings, in which some, but not all embodiments of the presently disclosed subject matter are shown. Like numbers refer to like elements throughout. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

[0034] Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.

[0035] Throughout this specification and the claims, the terms “comprise,” “comprises”, and “comprising” are used in a non-exclusive sense, except where the context requires otherwise. Likewise, the term “includes” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.I. Systems and Methods

[0036] In some aspects, the techniques described herein relate to an automated rail system, the system including: a first carriage structured to move along a first rail; a second carriage structured to move along a second rail; and a third rail connected to the first carriage at a first end of the third rail and the second carriage at a second end of the third rail, wherein at least one of the first carriage or the second carriage is connected to the third rail via an angular compliance mechanism, wherein the angular compliance mechanism allows the at least one of the first carriage or the second carriage to rotate relative to the third rail.

[0037] In some aspects, the techniques described herein relate to a system, further including an arm mechanism attached to the third rail, wherein the arm mechanism is moveable along the third rail between the first end and the second end.

[0038] In some aspects, the techniques described herein relate to a system, wherein the arm mechanism is extendable along an axis perpendicular to an axis along the third rail between the first end and the second end.

[0039] In some aspects, the techniques described herein relate to a system, wherein the first rail and the second rail are attached to a shelf.

[0040] In some aspects, the techniques described herein relate to a system, wherein the first carriage includes a position tracking mechanism, wherein the position tracking mechanism engages one or more tracking markers.

[0041] In some aspects, the techniques described herein relate to a system, wherein the one or more tracking markers are barcodes.

[0042] In some aspects, the techniques described herein relate to a system, wherein the first carriage and the second carriage are independently moved.

[0043] In some aspects, the techniques described herein relate to a system, further including a sensor, wherein the sensor determines that at least one of the first carriage or the third rail moves relative to the second carriage.

[0044] In some aspects, the techniques described herein relate to a system, wherein upon a change in a sensor reading of the sensor, the second carriage is moved along the second rail.

[0045] In some aspects, the techniques described herein relate to a system, wherein the first carriage and the second carriage are each connected to the third rail via an angular compliance mechanism.

[0046] In some aspects, the techniques described herein relate to a method of manufacturing an automated rail system.II. Example Use Cases

[0047] The present disclosure allows for improved laboratory automation that overcomes many of the physical constraints currently found in laboratory automation construction. Various embodiments provide a rail system that includes allows for movement along the Z axis with a SCARA arm attach that provides movement in along the X axis and the Y axis.

[0048] The first aspect of the rail system is that the mounting system that attaches the rail to the structure (e.g., a shelf and / or other structure) is adaptable (e.g., the carriages may adjust for non-parallel railing), which allows for alignment of the carriages while a third rail traverses the first rail and second rail mounted to the structure.

[0049] The compliance in the rail would mean that the connecting shaft (e.g., the third rail) itself cannot be a fixed length between the top and bottom rails, as the carriages may never be exactly aligned. As such, the rail system provides for an angular compliance mechanism on the connection between the third rail and at least one of the first carriage or the second carriage to allow the given carriage to rotate relative to the third rail to align the carriages for movement.

[0050] In order for the first carriage to know the position of the first carriage along the first rail, as well as permitting the rail system to be extensible, the system uses one or more tracking markers 210, as shown in FIGs. 2 and 8 (e.g., one row of barcodes the length of the first rail). The first carriage registers the position of the first carriage and then drives to prescribed locations using the tracking marker(s). The tracking marker(s) 210 may be provided on the second rail and / or other locations on the rail system to allow the system to determine the position of the rail system.

[0051] In various embodiments, the second carriage may have a motor to drive the second carriage along the second rail. In some embodiments, the second rail may not have tracking marker(s). Instead, the movement of the second carriage may be based on a sensor connected to the top carriage (e.g., the first carriage). Alternatively, the second carriage may be independently operated from the first carriage (e.g., using tracking marker(s) on the second rail). In some embodiments, the first rail may not have any tracking markers, and the second rail may have the tracking markers (e.g., the first carriage may travel based on a sensor positioned within the second carriage traveling along the second rail).

[0052] In various embodiments, the rail system, may use an analog optical sensor that is partially obstructed by an opaque flag. The sensor is mounted to either the second carriage or the third rail, and the flag is mounted to the other component (e.g., the second carriage or the third rail in which the sensor is not mounted). As the first carriage is commanded to move in either direction, the relationship between the flag and the sensor (given that the second carriage has not yet moved)would change, and the value being read by the optical sensor would either increase or decrease as the flag either obscures more or less of the sensor. The change in signal strength is used in an algorithm to then command the second carriage and associated motor to drive to restore the optical sensor signal to its nominal position. The sensor setup allows the whole rail and carriage system to be much lighter and reduces the strict positioning and tolerance requirements of the rail system to the instrumentation onboard that are present in most all other laboratory automation systems.

[0053] In various embodiments, the rail system may be entirely powered by battery and receives commands for move the carriages, the z-stage in z, and the SCARA arm entirely through Wi-Fi or radio communications. Such a configuration enables the system to be infinitely scalable by adding more units. Additionally, by employing battery power with wireless communication, the components of the rail system may be easily removed and / or replaced from the rail system.

[0054] Advantages of various embodiments include that the system being deployable and expandable by end users; the system being battery operated, arbitrarily replaceable, robots that can be removed from the system and replaced simply; the system supports charging the robot from arbitrary positions; the system uses compliant track mounting to solve the problem of linear track alignment in expandable systems; the system uses compliant coupling between robot and track to compensate for track angular misalignments; and the system uses an analog optical sensor partially obscured to keep the z-robotic assembly vertical, dramatically reducing the kinematic coupling requirements over that length.III. With Reference to the Figures

[0055] Referring now to FIG. 1, a rail system 100 is shown mounted on a structure 105 (e.g., a shelf). While the structure 105 is shown as a shelf structure, the rail system 100 may be mounted on any number of structures. As such, the term shelf or structure used herein may refer to any structure. For example, the rail system 100 may have an independent structure that is positioned adjacent a shelf structure and / or any other structure on which an arm is interacting. The structure 105 may include a removeable front column to allow for easy loading / unloading of large objects. The structure may include modular paneling to provide an airtight housing for the structure 105(e.g., for filtering and / or safety purposes). Any number of different structure attachments may be contemplated.

[0056] The rail system 100 may be used with various laboratory automation products. Example products for which the rail system may be used include laboratory automation products (e.g., STACK Intelligent Automation system by Formulatrix™, ROVER Autonomous Plate Handling by Formulatrix™, etc.), liquid handling products (e.g., Mantis Precise Liquid Dispenser by Formulatrix™, Tempest High-Throughput Dispenser by Formulatrix™, F.A.S.T. Positive Displacement Sample Transfer by Formulatrix™, FLO i8 PD General Purpose Liquid Handler by Formulatrix™), other products produced by Formulatrix™, and / or the like. Such products may be intergrated into a unified power supply and communications module, as well as controller board that allows for unified laboratory automation in an encapsulated environment.

[0057] The rail system 100 includes a first rail 110 and a second rail 115. A first carriage 125 (e.g., an upper carriage) may be mounted to move along the first rail 110 and a second carriage 130 (e.g., a lower carriage) may be mounted to move along the second rail 115. The first carriage 125 and the second carriage 130 may be connected via a third rail 120 (e.g., the first carriage 125 may be attached to a first end of the third rail 120 and the second carriage 130 may be positioned at a second end of the third rail 120 opposite the first end). The first carriage 125 may be mounted proximate to a first end of the third rail 120 and the second carriage 130 may be mounted proximate to a second end of the third rail 120 opposite the first end of the third rail 120.

[0058] In various embodiments, an arm mechanism 135 may be movably mounted to the third rail 120. The arm mechanism 135 may be a selective compliance assembly robot arm (SCARA) and / or other type of robotic arm. The arm mechanism 135 may have movements in multiple directions (e.g., along the X axis, and / or the Y axis). The movement along the third rail 120 provides for additional movement along the Z axis, allowing three-dimensional movement of a two-dimensional robotic arm. The arm mechanism 135 may have independent three-dimensional movement (e.g., in additional to the movement along the third rail via the belt drive discussed herein).

[0059] The arm mechanism 135 may move along the third rail 120 between the first carriage125 and the second carriage 130. The arm mechanism 135 may move within the structure 105 (e.g., the arm mechanism 135 may extend into and interact with objects held within the structure 105). The arm mechanism 135 may include a gripping mechanism allowing the arm mechanism 135 to engage with objects within the structure 105. In various embodiments, the arm mechanism 135 may have any type of object interaction interface allowing the arm mechanism 135 to engage with an object (e.g., finger and / or claw gripping mechanism, a spatula retrieval mechanism, and / or the like).

[0060] In various embodiments, the third rail 120 moves along a first axis (e.g., along the Z axis 150 travelled by the first carriage 125 and the second carriage 130). The arm mechanism 135 may also move along a second axis (e.g., along X axis 155 into and / or out of the structure to interact with objects within the structure) and / or a third axis (e.g., along Y axis 160 defined between the first carriage 125 and the second carriage 130). As such, the arm mechanism 135 may move along the third axis (e.g., Y axis 160) via movement along the third rail 120. The arm mechanism 135 may move along the third rail 120 via a belt movement mechanism. The arm mechanism 135 may include capabilities, such as an extendable arm, to extend along the second axis (e.g., the X axis 155). As such, during usage of the rail system, the rail system may move the arm mechanism 135 into position via movement of the third rail 120 along the first rail 110 and the second rail 115 (e.g., along the Z axis 150), movement of the arm mechanism 135 along the third rail 120 (e.g., along the Y axis 160), and / or actuation of the arm mechanism 135 along the X axis 155.

[0061] While the rail system shown in FIG. 1 is mounted to a shelf structure, the rail system disclosed may be used with various structures found in laboratory or manufacturing environments. For example, the rail system 100 may be attached to any assembly in which an automated retrieval system may be desired. As such, while the rail system is discussed herein as mounted to a shelf, the rail system may be used with other assemblies without changing the nature of the present disclosure.

[0062] In various embodiments, the first rail 110 and / or the second rail 115 may be extendable via a flexible coupling. In various embodiments, a flexible coupling may attach two portions ofrailings defined on different or the same structure to create a single rail (e.g., a first rail 110 or a second rail 115). For example, a flexible coupling may connect a railing on a first shelf and a railing on a second shelf. The carriages may travel along the flexible coupling to move from one portion of the rail to the other. As such, the rail system may be scalable across any number of different size structures. For example, the first rail and / or second rail may be extended across any length of a structure using one or more flexible coupling. In various embodiments, the different structures may include daisy chain power and / or ports (e.g., data and / or power ports) to allow for the rail system to be extended by coupling different structures together (e.g., multiple shelfs may be linked together).

[0063] The rail system may be moveable via a controller (e.g., including at least one processing device and at least one memory device). The controller may be able to control the carriages and / or the arm mechanism. The controller may be within the rail system and / or the rail system may be in communication with the controller and / or other computing devices that control the operations of the rail system (e.g., cause the first carriage, the second carriage, and / or the arm mechanism to move). As such, at least one processing device may determine a position of the tracking marker(s), determine the position of the first carriage, the second carriage, and / or the arm mechanism within the rail system, and determine movement of the first carriage, the second carriage, and / or the arm mechanism within the rail system.

[0064] While the rail system is illustrated with a first carriage, a second carriage, a single arm mechanism, any number of different carriages and / or arm mechanism may be used on the same rail system. For example, one or more additional rails (e.g., in addition to the third rail) may be provided and attached to independent carriages that also travel along the rails as the third rail discussed herein.

[0065] Any number of structures may include wheels, rollers, bearings or other mobile mechanisms to allow the rail system to be moved. The rail system may also be reusable (e.g., via removing the rails (e.g., the first rail and / or the second rail) and reinstalling the rails on a different structure).

[0066] Referring now to FIG. 2, an example rail (e.g., a first rail 110) of a rail system is shownattached to a structure 105. While the first rail is shown in FIG. 2, the structure and / or operations may extend to the second rail 115. For example, the second rail 115 may have the same or similar structure as the first rail 110. The first rail 110 and / or the second rail 115 may define one or more grooves to receive a carriage, as shown in FIG. 1.

[0067] In various embodiments, an attachment component 205 may be provided to allow the given rail (e.g., the first rail 110) to be attached. The attachment component 205 may be provided to receive a fastener, such as a screw, from the given rail to attach the rail to the structure 105. Additionally, or alternatively, the attachment component 205 may be magnetic (e.g., to create a magnetic attachment with the given rail). As shown in FIG. 2., the attachment component 205 may receive a fastener that is provided through the given rail and the shelf. In various embodiments, the given rails may be attached to the structure 105 (e.g., the shelf) exclusively (e.g., the assembly may be structured to withstand the weight and force of the rail system). Alternatively, additional support, such as the attachment component 205 may be provided to provide additional support.

[0068] One or more tracking marker(s) 210 may be defined along and / or adjacent to the first rail 110 and / or the second rail 115. The tracking marker(s) 210 may be aligned with the position tracking mechanism 300 discussed herein during operation, such that the position tracking mechanism 300 may scan and / or otherwise process one or more tracking markers during operation. Example tracking marker(s) are discussed in reference to FIGs. 2 and 8.

[0069] In various embodiments, the system may determine positioning of the given carriage based on the content of the tracked markers scanned and / or the number of markers scanned. For example, the system may determine absolute location of a given carriage via the scan of different markers along the rail 110 (e.g., as shown in FIG. 8, the given rail may have multiple distinct tracking markers defined along the rail and the position of the distinct tracking markers may be known to the system to determine a location of the given carriage). Additionally or alternatively, the system may determine relative location via counting the number of markers scanned during movement of the carriage. While the tracking marker(s) 210 are shown along the first rail 110 in FIG. 2, tracking marker(s) may be provided on the second rail 115 instead of or in addition to the markers 210 of the first rail. As such, the position of the first carriage (on the first rail 110) and / orthe second carriage (on the second rail 115) may be determined. The position of the third rail may be determined based on the position of the first carriage and / or the second carriage. In various embodiments, tracking marker(s) may be provided along the third rail to monitor the position of the arm mechanism 135 along the third rail.

[0070] Referring now to FIG. 3, an example carriage (e.g., first carriage 125) is shown. The first carriage 125 may include one or more rail engagement mechanisms that provide engagement between the first carriage and the first rail 110. For example, the first carriage may include one or more wheels (e.g., wheels 305, 310, 315). The wheel(s) may include one or more grooves to engage the first rail 110. At least one of the wheels may be automatically rotated (e.g., driven by a motor to move the first carriage 125 along the first rail 110). One or more wheels may spin freely and not be automated or engaged by a motor (e.g., rotates based on the movement of the first carriage). The number of driven wheels and the non-driven wheels may be based on the design of the rail system, as well as the speed in which the first carriage is to be moved (e.g., more driven wheels may result in faster movement by the rail system), and the weight or required force of move the carriage, including the overall size of the carriage and products onboard. The example carriage 125 may be used as a first carriage 125 and / or a second carriage 130.

[0071] At least one of the carriages (e.g., the first carriage 125 and / or the second carriage 130) of the rail system may include a position tracking mechanism 300 (e.g., a barcode scanner, RFID, camera, and / or other optical sensing device). In various embodiments, one or more tracking markers (e.g., barcode and / or other marker) may be placed adjacent and / or along the first rail 110 (e.g., along the structure 105 and / or directly on the given rail, as shown in FIGs. 2 or 8). As such, the position tracking mechanism 300 may scan or otherwise engage with one of the tracking markers to determine the location (e.g., along the Z axis 150 shown in FIG. 1).

[0072] The tracking markers may be organized in a row (e.g., along the Z axis 150 shown in FIG. 1), such that the position tracking mechanism 300 of the first carriage 125 may scan or otherwise engage with the tracking marker(s) during movement and / or upon stopped along the first rail 110. While the position tracking mechanism 300 is shown on the first carriage 125, in various embodiments, the second carriage 130 may either additionally or alternatively include aposition tracking mechanism 300 (e.g., the tracking marker(s) may be positioned adjacent to the second rail 115). As such, the position of the second carriage 130 may be determined based on tracking marker(s) using a position tracking mechanism.

[0073] In various embodiments, the first carriage 125 may be coupled to the third rail 120, such that movement of the first carriage 125 causes the third rail to move. In various embodiments, the first carriage 125 may include an angular compliance mechanism 320. The angular compliance mechanism 320 may be the point at which the first carriage 125 is attached to the third rail 120. In various embodiments, the angular compliance mechanism 320 may provide a pivot point for the first carriage 125 relative to the third rail 120. The angular compliance mechanism 320 may be fixed (e.g., not allowing any movement of the third rail relative the first carriage 125) and / or free pivoting (e.g., allowing for the third rail 120 to rotate relative to the first carriage 125). In various embodiments, the system may adjust the angular compliance mechanism 320 between a fixed position configuration and the free pivoting configuration (e.g., the system may detect an optimal angle between the first carriage and the third rail and fix the angular compliance mechanism at the optimal angle).

[0074] The first carriage 125 and the third rail 120 may be attached to each other via a connecting component 325. The connecting component 325 may be part of the third rail 120 (and attached to the first carriage 125) or attached to both the third rail 120 and the first carriage 125. The angular compliance mechanism 320 may include a bearing allowing the first carriage 125 to rotate relative to the third rail 120. The bearing of the angular compliance mechanism 320 may be part of the first carriage 125 or the connecting component 325. In various embodiments, the angular compliance mechanism 320 allows rotation of the first carriage 125 relative to the third rail 120, such as to traverse misaligned tracks (e.g., in an instance in which the first rail 110 and the second rail 115 are not parallel). An example of an angular compliance mechanism being used in shown in FIG. 5 in which the angular compliance mechanism of the second carriage 130 is rotated to compensate for a misaligned rail. In various embodiments, each carriage (e.g., a first carriage 125 and a second carriage 130) may have an angular compliance mechanism. Alternatively, only a single carriage may have an angular compliance mechanism.

[0075] The belt drive 330 of the third rail 120 is shown in FIG. 3. The belt drive 330 may be used to move the arm mechanism 135 along the Y axis 160, as discussed in reference to FIG. 1. In various embodiments, the belt drive 330 may be actuated by a motor. The motor may be the same or independent from the motors used to move the first carriage and / or the second carriage.

[0076] As discussed in more detail below in reference to FIG. 6, the first carriage (and / or the second carriage) may include a charging receptor 350. The charging receptor 350 may allow for inductive charging (e.g., via the charging panel 600 of FIG. 6).

[0077] Referring now to FIG. 4, another example carriage (e.g., a second carriage 130) is shown. In various embodiments, the second carriage 130 may include the same or similar components as the first carriage 125. For example, the second carriage 130 may include at least one wheel (e.g., wheels 405, 410), an angular compliance mechanism 420, and / or the like.

[0078] While the example carriage of FIG. 4 does not include a position tracking mechanism, a position tracking mechanism, such as the position tracking mechanism 300 may be provided. For example, the second carriage 130 may have a position tracking mechanism that is the same as the position tracking mechanism 300 of the first carriage 125 in FIG. 1.

[0079] In various embodiments, one or more wheel(s) 405, 410 may be driven (e.g., rotated via a motor). For example, the wheel 405 may be drive by a motor. Additionally, or alternatively, one or more wheels may not rotate directly by a motor and instead rotate based on the movement of the first carriage (e.g., only one of the first carriage or second carriage may be motorized and the other carriage may move based on the connection to the third rail). While FIG. 4 shows two wheels on the second carriage 130, the second carriage may include any number of wheels (e.g., three wheels as the first carriage in FIG. 3). In various embodiments, the wheels of the first carriage and / or second carriage may not be rotated directly by a motor (e.g., the wheel(s) of the first carriage may cause the movement and the wheels of the second carriage may merely rotate based on the movement caused by the first carriage).

[0080] The angular compliance mechanism 420 may include a bearing and also include the functionality of the angular compliance mechanism 320 discussed in reference to FIG. 3. For example, the angular compliance mechanism 420 allows the second carriage to rotate relative tothe third rail 120. The angular compliance mechanism 420 may be the attachment point for the second carriage 130 and the third rail 120 (via the connecting component 425). An example of an angular compliance mechanism 420 being used in shown in FIG. 5 in which the angular compliance mechanism of the second carriage 130 is rotated to compensate for a misaligned rail. In various embodiments, each carriage (e.g., a first carriage 125 and a second carriage 130) may have an angular compliance mechanism. Alternatively, only a single carriage may have an angular compliance mechanism.

[0081] The second carriage 130 and the third rail 120 may be attached via a connecting component 425. The connecting component 425 may be part of the third rail 120 (and attached to the second carriage 130) or attached to both the third rail 120 and the second carriage 130. The connecting component 425 may include the same or similar structure as the connecting component 325 of FIG. 3. In various embodiments, the connecting component 425 is rigidly attached to the third rail 120, such that the connecting component 425 does not move relative to the third rail 120. The connecting component 425 is rotatably attached to the second carriage 130 via the angular compliance mechanism 420.

[0082] The second carriage 130 may include a sensor to determine location relative to the first carriage 125. As such, the second carriage 130 may be moved based on the change in the sensor reading due to movement of the first carriage 125. The sensor may be an analog optical sensor partially obstructed by an opaque flag. The sensor is mounted to either the second carriage or the third rail, and the flag is mounted to the second carriage or the third rail (whichever one the sensor was not mounted). As the first carriage 125 is commanded to move in either direction along the Z axis 150, the relationship between the flag and the sensor (given that the second carriage 130 has not yet moved) would change, and the value being read by the optical sensor would either increase or decrease as the flag either obscures more or less of the sensor. Based on the change in value, the system may determine which direction the second carriage 130 along the Z axis 150. To do this, the system uses the change in signal strength in an algorithm to then command the second carriage 130 and associated motor to drive to restore the optical sensor signal to its nominal position (e.g., aligned with the first carriage). As such, the second carriage 130 reacts and “keepsup” with the first carriage 125 during movement.

[0083] Referring now to FIG. 5, an example rail system is shown being used in an instance in which a first rail and a second rail are not aligned. As shown, the first rail 110 and the second rail 115 are not parallel. As such, a typical rigid connection may cause a malfunction. Instead, in various embodiments, as shown the first carriage 125 and / or the second carriage 130 may include an angular compliance mechanism (e.g., the angular compliance mechanism 320 of the first carriage 125 and / or the angular compliance mechanism 420 of the second carriage 130). The angular compliance mechanism may act as a pivot point to allow the third rail 120 to rotate relative to the given carriage.

[0084] In the example shown in FIG. 5, the second rail 115 is not mounted parallel to the first rail 110 (e.g., due to mounted incorrectly, change over time, differences in structure in which the rail system is attached, etc.) The second rail 115 includes an angular error 500. As such, the angular compliance mechanism 420 allows the second carriage 130 and the third rail 120 to rotate relative to one another to allow for the second carriage 130 to move along the second rail 115 without being jammed. The third rail 120 may also include flexibility to allow for the third rail to stretch or otherwise change shape based on the angular error 500.

[0085] Referring now to FIG. 6, an example rail system is shown with a charging rail mounted to charge the rail system. The carriages (e.g., the first carriage 125, the second carriage 130, etc.) and / or the third rail 120 may be electrically powered in order to cause actuation of the various motors discussed herein (e.g., to move the carriages and / or the arm mechanism). One or more batteries may be used on the rail system to allow them to easily be installed, moved, extended, and / or the like. FIG. 6 illustrates an instance in which a charging panel is installed to allow the batteries to be recharged. As shown, the charging panel 600 may be an inductive charging panel.

[0086] The charging panel 600 may be mounted adjacent to one of the rails (e.g., the first rail 110 as shown in FIG. 6 and / or the second rail 115). In various embodiments, charging panel 600 may charge one or more batteries used to actuate components of the rail system. In various embodiments, the charging panel 600 may charge a single battery associated with the rail system, which in turn charges other batteries in the rail system. Additionally, or alternatively, one or morebateries may be rechargeable and / or replaceable independent of the charging panel 600. Any number of batteries, capacitors, super capacitors, and / or other power sources / storage devices may be used.

[0087] In various embodiments, at least one of the carriages may include a charging receptor, such as the charging receptor 350 shown in FIG. 3, that engages with the charging panel 600 to charge the one or more bateries. The charging receptor 350 may be provided on the first carriage and / or the second carriage. As the charging receptor 350 moves along the charging panel 600, the one or more bateries are changed (e.g., via inductive charging). The charging panel 600 may be selectively powered (e.g., the one or more bateries of the rail system may be charged until a threshold amount and the charging panel 600 may be deactivated until the one or more batteries need additional charge). Alternatively, the charging panel 600 may be continuously powered.

[0088] While the charging panel 600 is provided at approximately the same length as the first rail, the charging panel 600 may be less than the entire length of the given rail (e.g., the charging panel 600 may only be a portion of the length of the given rail, such that the given carriage is only charged during a portion of movement along the given rail). In various embodiments, the charging panel 600 may be unitary and / or atached to the given rail (e.g., the first rail 110 as shown in FIG. 6 and / or the second rail 115). Alternatively, the charging panel 600 may be distinct from the given rail (e.g., atached to the structure 105 directly).

[0089] Referring now to FIG. 7, a flowchart 700 of manufacturing a rail system in accordance with various embodiments is shown. The operations discussed herein may be used to carry out the manufacture of any of the embodiments discussed herein.

[0090] Referring now to Block 710 of FIG. 7, the method includes providing a first carriage structured to move along a first rail. The first carriage 125 is discussed in reference to at least FIGs. 1, 3, 5 and 6 herein. The first carriage 125 is atachable to the first rail 110 and moveable along the first rail 110. The first carriage 125 is attached to the third rail 120. The first carriage 125 may include a position tracking mechanism 300 as discussed in reference to FIG. 3, which engage with location marker(s) (e.g., barcodes).

[0091] Referring now to Block 720 of FIG. 7, the method includes providing a second carriagestructured to move along a second rail. The second carriage 130 is discussed in reference to at least FIGs. 1, 4, 5 and 6 herein. The second carriage 130 is attachable to the second rail 115 and moveable along the second rail 115. The second carriage 130 is attached to the third rail 120 at an end opposite the first carriage 125. The first rail 110 and / or the second rail 115 may be attached to a structure, such as a shelf.

[0092] The first carriage 125 and the second carriage 130 may be independently moved. In various embodiments, as discussed in reference to FIG. 4, the second carriage 130 may be moved in response to a change in a sensor reading of a sensor that detects movement of the third rail 120 and / or the first carriage 125 relative to the second carriage 130. The first carriage 125 and / or the second carriage 130 may be powered via the charging discussed in reference to FIG. 6. The first carriage 125 and the second carriage 130 may be electronically connected via the third rail (e.g., the first carriage 125 may be connected to the second carriage 130 via wiring passing through the third rail). The first carriage 125 and / or the second carriage 130 may also be electrically connected to the arm mechanism 135.

[0093] Referring now to Block 730 of FIG. 7, the method includes connecting a third rail to the first carriage at a first end of the third rail and the second carriage at a second end of the third rail. The third rail 120 is discussed in reference to at least FIGs. 1 and 3-6 herein. As discussed herein, at least one of the first carriage or the second carriage is connected to the third rail via an angular compliance mechanism. In such an instance, the angular compliance mechanism allows the at least one of the first carriage or the second carriage to rotate relative to the third rail. As such, the first carriage and / or the second carriage may be adjustable to allow for the first rail and the second rail to be non-parallel.

[0094] Referring now to optional Block 740 of FIG. 7, the method includes attaching an arm mechanism to the third rail. In various embodiments, the arm mechanism is moveable along the third rail between the first end and the second end. An example arm mechanism 135 is discussed in reference to FIG. 1 herein. In various embodiments, the arm mechanism is extendable along an axis perpendicular to an axis along the third rail between the first end and the second end.

[0095] Referring now to FIG. 8, tracking marker(s) 210 on a first rail 110 is shown. Asdiscussed herein, the tracking marker(s) 210 may be positioned on the first rail 110, the second rail 115, and / or the structure 105. The tracking marker(s) 210 of FIG. 8 illustrate distinct markers in which each tracking marker may represent a specific position along the given rail. The tracking marker(s) 210 may also be known as fiducial markers. The tracking marker(s) may include encoded markings. The encoded markings (e.g., as shown as the dots within the tracking markers of FIG. 8) may provide visual position feedback information to the rail system based on scanning and / or interaction by the position tracking mechanism 300 (shown in FIG. 3). In an example in which encoded markings are used for the tracking markers, the tracking marker(s) 210 include encoded markings that can be associated with a position in the workspace. For example, the rail system may include a rail (e.g., first rail 110) that includes an arrangement or grid of tracking marker(s) 210 with each of the tracking markers being uniquely encoded to correspond to a physical position along the given rail.

[0096] In an example embodiment, each of the tracking marker(s) 210 may be about 15 millimeters square. In one example, each of the tracking marker(s) 210 may be uniquely encoded using a line of markers, such as is shown in FIG. 8. The position of the tracking marker(s) 210 along the given rail may correspond to the structure 105. For example, the system may determine a location of the carriage(s) and / or third rail relative to the structure 105.

[0097] In various embodiments, the tracking marker(s) 210 may include a barcode / QR code. In such an instance, the position tracking mechanism 300 may include a camera or other visual mechanism (e.g., a barcode scanning device) to identify and / or process the barcodes. In various embodiments, each tracking marker(s) 210 may be a uniquely encoded RFID tag and the position tracking mechanism 300 may include a downward-facing RFID reader. In various embodiments, the position tracking mechanism 300 may be able to scan and / or otherwise engage with any number of different types of markers (e.g., encoded markers, barcode / QR code markers, RFID tag markers, and / or the like). The first carriage 125 and / or the second carriage 130 may include a position tracking mechanism 300. As such, the rail system may determine the position of the first rail (e.g., via a position tracking mechanism 300 on the first carriage 125), the second carriage (e.g., via a position tracking mechanism 300 on the second carriage 130), the arm mechanism 135,and / or the third rail.

[0098] The tracking marker(s) 210 shown in FIG. 8 provides a 2D coordinate system, the first carriage and / or the second carriage may navigate along the given rail without any additional positioning necessary. Any number of different shapes may be used for the tracking marker(s) 210 (e.g., square, circular, triangular, etc.). The tracking marker(s) 210 may be spaced based on the desired precision of the rail system. For example, some use cases may include engaging with small objects that require very precise positioning, while others may allow for greater tolerances (e.g., a large object may not need as precise engagement as a small object). The tracking marker(s) 210 may be adjustable (e.g., automatically and / or manually) based on the type of use case for the rail system (e.g., the type of structure 105 for which the rail system is being used).

[0099] The systems discussed herein may be used with any of the embodiments discussed in reference to related PCT applications filed concurrently with the present disclosure. As such, the PCT applications titled “OBJECT TRANSPORTATION AND GRIPPING DEVICE” and “ALIGNMENT SYSTEM FOR AUTOMATED OBJECT TRANSFER” filed on May 20, 2025, are hereby incorporated by reference. The present disclosure will be updated to include application numbers after filing.

[0100] It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the abovedescribed embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.IV. Claim Clauses

[0101] Clause 1. An automated rail system, the system comprising: a first carriage structured to move along a first rail; a second carriage structured to move along a second rail; and a third rail connected to the first carriage at a first end of the third rail and the second carriage at a second end of the third rail, wherein at least one of the first carriage or the second carriage is connected to the third rail via an angular compliance mechanism, wherein the angular compliance mechanismallows the at least one of the first carriage or the second carriage to rotate relative to the third rail.

[0102] Clause 2. The system of Clause 1, further comprising an arm mechanism attached to the third rail, wherein the arm mechanism is moveable along the third rail between the first end and the second end.

[0103] Clause 3. The system of Clause 2, wherein the arm mechanism is extendable along an axis perpendicular to an axis along the third rail between the first end and the second end.

[0104] Clause 4. The system of Clause 1, wherein the first rail and the second rail are attached to a shelf.

[0105] Clause 5. The system of Clause 1, wherein the first carriage comprises a position tracking mechanism, wherein the position tracking mechanism engages one or more tracking markers.

[0106] Clause 6. The system of Clause 5, wherein the one or more tracking markers are barcodes.

[0107] Clause 7. The system of Clause 1, wherein the first carriage and the second carriage are independently moved.

[0108] Clause 8. The system of Clause 7, further comprising a sensor, wherein the sensor determines that at least one of the first carriage or the third rail moves relative to the second carriage.

[0109] Clause 9. The system of Clause 8, wherein upon a change in a sensor reading of the sensor, the second carriage is moved along the second rail.

[0110] Clause 10. The system of Clause 1, wherein the first carriage and the second carriage are each connected to the third rail via an angular compliance mechanism.

[0111] Clause 11. A method of manufacturing an automated rail system, the method comprising: providing a first carriage structured to move along a first rail; providing a second carriage structured to move along a second rail; and connecting a third rail to the first carriage at a first end of the third rail and the second carriage at a second end of the third rail, wherein at least one of the first carriage or the second carriage is connected to the third rail via an angular compliance mechanism, wherein the angular compliance mechanism allows the at least one of the 1first carriage or the second carriage to rotate relative to the third rail.

[0112] Clause 12. The method of Clause 11, further comprising attaching an arm mechanism to the third rail, wherein the arm mechanism is moveable along the third rail between the first end and the second end.

[0113] Clause 13. The method of Clause 12, wherein the arm mechanism is extendable along an axis perpendicular to an axis along the third rail between the first end and the second end.

[0114] Clause 14. The method of Clause 11, wherein the first rail and the second rail are attached to a shelf.

[0115] Clause 15. The method of Clause 11, wherein the first carriage comprises a position tracking mechanism, wherein the position tracking mechanism engages one or more tracking markers.

[0116] Clause 16. The method of Clause 15, wherein the one or more tracking markers are barcodes.

[0117] Clause 17. The method of Clause 11, wherein the first carriage and the second carriage are independently moved.

[0118] Clause 18. The method of Clause 17, further comprising providing a sensor, wherein the sensor determines that at least one of the first carriage or the third rail moves relative to the second carriage.

[0119] Clause 19. The method of Clause 18, wherein upon a change in a sensor reading of the sensor, the second carriage is moved along the second rail.

[0120] Clause 20. The method of Clause 11, wherein the first carriage and the second carriage are each connected to the third rail via an angular compliance mechanism.

Claims

CLAIMSTherefore, the following is claimed:

1. An automated rail system, comprising: a first carriage structured to move along a first rail; a second carriage structured to move along a second rail; and a third rail connected to the first carriage at a first end of the third rail and the second carriage at a second end of the third rail, wherein at least one of the first carriage or the second carriage is connected to the third rail via an angular compliance mechanism, wherein the angular compliance mechanism allows the at least one of the first carriage or the second carriage to rotate relative to the third rail.

2. The system of Claim 1, further comprising an arm mechanism attached to the third rail, wherein the arm mechanism is moveable along the third rail between the first end and the second end.

3. The system of Claim 2, wherein the arm mechanism is extendable along an axis perpendicular to an axis along the third rail between the first end and the second end.

4. The system of Claim 1, wherein the first rail and the second rail are attached to a shelf.

5. The system of Claim 1, wherein the first carriage comprises a position tracking mechanism, wherein the position tracking mechanism engages one or more tracking markers.

6. The system of Claim 5, wherein the one or more tracking markers are barcodes.

7. The system of Claim 1, wherein the first carriage and the second carriage are independently moved.

8. The system of Claim 7, further comprising a sensor, wherein the sensor determines that at least one of the first carriage or the third rail moves relative to the second carriage.

9. The system of Claim 8, wherein upon a change in a sensor reading of the sensor, the second carriage is moved along the second rail.

10. The system of Claim 1, wherein the first carriage and the second carriage are each connected to the third rail via an angular compliance mechanism.

11. A method of manufacturing an automated rail system, comprising: providing a first carriage structured to move along a first rail; providing a second carriage structured to move along a second rail; and connecting a third rail to the first carriage at a first end of the third rail and the second carriage at a second end of the third rail, wherein at least one of the first carriage or the second carriage is connected to the third rail via an angular compliance mechanism, wherein the angular compliance mechanism allows the at least one of the first carriage or the second carriage to rotate relative to the third rail.

12. The method of Claim 11, further comprising attaching an arm mechanism to the third rail, wherein the arm mechanism is moveable along the third rail between the first end and the second end.

13. The method of Claim 12, wherein the arm mechanism is extendable along an axis perpendicular to an axis along the third rail between the first end and the second end.

14. The method of Claim 11, wherein the first rail and the second rail are attached to a shelf.

15. The method of Claim 11, wherein the first carriage comprises a position tracking mechanism, wherein the position tracking mechanism engages one or more tracking markers.

16. The method of Claim 15, wherein the one or more tracking markers are barcodes.

17. The method of Claim 11, wherein the first carriage and the second carriage are independently moved.

18. The method of Claim 17, further comprising providing a sensor, wherein the sensor determines that at least one of the first carriage or the third rail moves relative to the second carriage.

19. The method of Claim 18, wherein upon a change in a sensor reading of the sensor, the second carriage is moved along the second rail.

20. The method of Claim 11, wherein the first carriage and the second carriage are each connected to the third rail via an angular compliance mechanism.

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