Sample container handling apparatus having electromagnetic rack retention mechanism

Abstract

An apparatus for handling a sample container of the type used in an analytical laboratory. The apparatus has a surface for supporting (i) a magnetically active sample container holder or (ii) a magnetically active sample container holder carrier. The apparatus also has a robotic gripper configured to lift a sample container from a sample container holder supported by the surface. Electromagnets are disposed about the support surface. A controller / processor of the apparatus is configured to selectively activate one or more of the electromagnets. The activation attracts the sample container holder or the sample container holder carrier toward the surface.

Description

SAMPLE CONTAINER HANDLING APPARATUS HAVING ELECTROMAGNETIC RACK RETENTION MECHANISMFIELD

[0001] The present disclosure relates to sample handling systems used in analytical laboratory settings. The disclosure is applicable at least to equipment of the type used in high throughput analytical laboratories, and also equipment used in smaller scale applications.BACKGROUND

[0002] Automation has revolutionized the operation of analytical and research laboratories. By integrating advanced robotics, instrumentation, and software, laboratory automation optimizes workflows, enhances process reproducibility, as well as reducing labor costs

[0003] At its core, laboratory automation aims to streamline experimental workflows by replacing manual tasks with automated processes. This involves the integration of robotic systems capable of performing a wide array of tasks, ranging from sample preparation and handling, sample analysis, output data analysis and storage.

[0004] Laboratory automation encompasses a diverse array of methodologies tailored to specific process requirements. Liquid handling robots, equipped with precision pipetting systems, enable accurate dispensing of reagents and samples, facilitating high-throughput screening and assay development. Integrated robotic workstations automate sample preparation workflows, including DNA extraction, purification, and amplification, revolutionizing genomics and molecular biology research. High-content imaging systems coupled with automated analysis software enable rapid acquisition and analysis of large-scale image datasets, empowering researchers in drug discovery and cell biology.

[0005] Automation is especially prevalent in high throughput analytical laboratories of the type used to analyze samples of clinical, environmental and industrial origin. Such laboratories are tasked with performing analysis on hundreds or thousands of individual samples per day, and automation is absolutely essential to operations.

[0006] In the context of a sample handling system, a number of sample tubes may be held in a rack of some description. The sample handling system may comprise a workstation having a tray area for receiving one or more sample racks. An exemplary workstation is the PathFinder™ 350A (Brooks Automation, USA), being a benchtop robotic workstation designed for the post-analytical archiving of sample tubes. Another type of robotic workstation is the PathFinder™ 450S (Brooks Automation, USA), used for pre-analytical sorting, tracking, and post-analytical storage sample tubes.

[0007] The tray of the workstation may comprise a number of fences which run across the tray and function to engage with and properly position the sample racks. The engagement is normally by way of a horizontally orientated spring-loaded member extending from the rack fence into a complimentary cavity in the lateral wall of the sample rack. Normally a sample rack is sandwiched between two rack fences, with each fence having multiple spring-loaded members along its length so as to securely engage with the tube rack at multiple points.

[0008] Such workstations also generally comprise a robotic gripper which vertically lifts a sample tube from its rack. The sample tube may be lifted for transport by the robotic gripper to another rack, where it is released.

[0009] It is not uncommon for a sample tube to become jammed in its sample rack. Upon vertical lifting of the tube by the robotic gripper, the entire rack may be lifted and become airborne. Conventional workstations avoid such lifting by the spring-loaded member engagement between the rack fence and the rack tube as discussed supra. While that approach is generally workable, the rack fences are complex to manufacture, expensive, and not readily compatible with otherhardware in a sample handling system. Moreover, some dexterity is required on the part of the operator to horizontally slide the sample rack between two rack fences.

[0010] Thus, the exists a need for an alternative or an improved approach to prevent a robot gripper from lifting an entire rack where a tube being lifted is jammed or otherwise inadvertently engaged with its rack.

[0011] As will be appreciated, the conventional arrangement of spring-loaded engagement of tube racks has the advantage of drawing no power whatsoever from the workstation. It is therefore generally desirable for any alternative or improvement to that conventional approach does not draw sufficient power so as to destabilize a conventional workstation power supply, or require any upgrade in the power supply.

[0012] The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present disclosure. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each provisional claim of this application.SUMMARY

[0013] In a first aspect, which is not necessarily the broadest aspect, there is provided an apparatus for handling a sample container, the apparatus comprising: a surface for supporting (i) a magnetically active sample container holder or (ii) a magnetically active sample container holder carrier, a robotic gripper configured to lift a sample container from a sample container holder supported by the surface, a plurality of electromagnets disposed about the support surface, and a controller / processor configured to selectively activate one or more of the plurality of electromagnets, wherein activation of one or more of the plurality of electromagnets attracts the sample container holder or the sample container holder carrier toward the surface.

[0014] In one embodiment of the first aspect, the electromagnetic attraction is at least sufficient to resist a lifting force of the robotic griper.

[0015] In one embodiment of the first aspect, controller / processor is configured to input locational information in relation to a sample container holder or a sample container holder carrier about the surface, and depending on the input locational information selectively activate one or more of the plurality of electromagnets.

[0016] In one embodiment of the first aspect, the controller / processor activates one or more of the plurality of electromagnets for at least the period of time that the robotic gripper lifts a sample container from a sample container holder about the surface, and deactivates the activated one or more of the plurality of electromagnets when the lifting ceases, or within 10 sec, 30 sec, 1 min, 2 min, 3 min, 4 min, 5 min, 6 min, 7 min, 8 min, min or 10 min after lifting ceases.

[0017] 5. In one embodiment of the first aspect, the one or more plurality of electromagnets are flush with the surface, or disposed below the surface, or are proud of the surface at a height of less than about 5 mm, 4 mm, 3 mm, 2 mm, 1 mm or 0.1 mm.

[0018] In one embodiment of the first aspect, the surface is provided by a tray configured in terms of material and / or thickness to allow at least about 50%, 50%, 70%, 80%, 90% or 95% of the magnetic field strength generated by the plurality of electromagnets to act on a sample container holder or a sample container holder carrier about the surface.

[0019] In one embodiment of the first aspect, the plurality of electromagnets are disposed substantially regularly across the surface.

[0020] In one embodiment of the first aspect, the plurality of electromagnets comprises at least or about 3, 4, 5, 6, 7, 8, 9 or 10 electromagnets.

[0021] In one embodiment of the first aspect, a sample container about the surface is configured to retain a plurality of sample tubes, each sample tube having a diameter between about 10 mm and about 25 mm.

[0022] In one embodiment of the first aspect, the apparatus comprises one or more arranging elements configured to alignment and / or position and / or orient a sample container holder and / or the sample container holder carrier with reference to an axis of the surface.

[0023] In one embodiment of the first aspect, the surface is generally rectangular and the axis is a short axis.

[0024] In one embodiment of the first aspect, the one or more arranging elements presents a space into which a sample container holder, or a sample container holder carrier, is locatable within.

[0025] In one embodiment of the first aspect, the one or more arranging elements present a ramp running downwardly to the space.

[0026] In one embodiment of the first aspect, the one or more arranging elements are configured to locate a sample container holder, or a sample container holder carrier, in a x, y-location across the surface, and optionally a z-location above the surface.

[0027] In one embodiment of the first aspect, the one or more arranging elements, and / or a sample container holder, and / or a sample container holder carrier is / are configured so as to allow contact between the surface and the sample container holder, or the sample container holder carrier.

[0028] In one embodiment of the first aspect, the one or more arranging elements are releasably engageable with the apparatus so as to be locatable about the surface.

[0029] In one embodiment of the first aspect, the one or more arranging elements is each comprised of paired parallel members mutually spaced so as to allow a sample container holder, or a sample container holder carrier to sit thereon and / or therebetween.

[0030] In one embodiment of the first aspect, the apparatus is configured as a floor-standing or bench-top workstation for robotically handling sample containers having a capacity of between about 1 mL and about 50 mL, the handling forming part of a sample handling workflow in an analytical laboratory.

[0031] In a second aspect there is provided a system comprising the apparatus of any embodiment of the first aspect, a sample container holder optionally carrier by a sample container holder carrier, and a sample container disposed in the sample container holder, wherein the system is configured such that lifting of a sample container that is jammed in the sample container holder by the robotic gripper is prevented by one or more of the plurality of electromagnets.

[0032] In one embodiment of the second aspect, the sample container holder and the sample container holder carrier are mutually engaged such that a lifting force applied to a sample container jammed in the sample container holder is transferred to the sample container holder carrier.BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The foregoing aspects and other features of the disclosed embodiment are explained in the following description, taken in connection with the accompanying drawings, wherein:

[0034] FIG. 1 is a diagrammatic illustration in upper perspective view of a first exemplary sample handling apparatus.

[0035] FIG. 2 is a diagrammatic illustration in upper perspective view of a second exemplary sample handling apparatus.

[0036] FIG. 3 is an illustration in upper perspective view of an exemplary tube sorting sample workstation.

[0037] FIG. 4 is an illustration of the workstation of FIG. 3 showing greater detail.

[0038] The drawings are not prepared to any particular scale or dimension and are not presented as being a completely accurate presentation of the various embodiments.DETAILED DESCRIPTION

[0039] After considering this description it will be apparent to one skilled in the art how the disclosure is implemented in various alternative embodiments and alternative applications. However, although various embodiments of the present disclosure will be described herein, it is understood that these embodiments are presented by way of example only, and not limitation. As such, this description of various alternative embodiments should not be construed to limit the scope or breadth of the present disclosure. Furthermore, statements of advantages or other aspects apply to specific exemplary embodiments, and not necessarily to all embodiments, or indeed any embodiment covered by the claims.

[0040] Throughout the description and the claims of this specification the word "comprise" and variations of the word, such as "comprising" and "comprises" is not intended to exclude other additives, components, integers or steps.

[0041] Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may.

[0042] As used herein, positional terms such as "lateral", "across", "above", "below", "higher", "lower", "upward", "downward", "plan view" and the like are to be considered with reference to a sample transport system as used in a normal upright position such that the opening of a liquid sample container under transport faces generally upwardly.

[0043] It will be appreciated that not all embodiments of the disclosure described herein have all of the advantages disclosed herein. Some embodiments may have a single advantage, while other may have no advantage at all and are merely a useful alternative to the prior art.

[0044] Any feature disclosed in the context of a particular embodiment of the disclosure may be used in any other embodiment described, claimed or drawn herein.

[0045] In a first aspect, there is provided an apparatus for handling a sample container, the apparatus comprising: a surface for supporting (i) a magnetically active sample container holder or (ii) a magnetically active sample container holder carrier, a robotic gripper configured to lift a sample container from a sample container holder supported by the surface, a plurality of electromagnets disposed about the support surface, and a controller / processor configured to selectively activate one or more of the plurality of electromagnets, wherein activation of one or more of the plurality of electromagnets attracts the sample container holder or the sample container holder carrier toward the surface.

[0046] It will be understood that the apparatus does not necessarily include a sample container holder, but may do so in some embodiments. A user may use a conventional sample carrier holder, such as a test tube rack, supplied separately to the apparatus.

[0047] It will be further understood that the apparatus does not necessarily include a sample container holder carrier, but may do so in some embodiments.

[0048] The present disclosure is predicated at least in part on the finding that an electromagnet may be used in a sample handling workstation (being a species of an apparatus) to retain a tube rack (being a species of sample container holder) on a specimen tray (being a species of a surface) of the workstation so as to prevent lifting a sample container from its holder when a robotic gripper attempts to remove a jammed sample container from its holder.

[0049] The magnetic attraction may be at least sufficient to counteract the lifting force exerted by the gripper, thereby preventing the tube rack from lifting from the specimen tray and becoming airborne. That requirement may guide the selection of an appropriate electromagnet for any given application. In certain embodiments, the electromagnet is configured to counteract a lifting force expected of a robotic gripper in a workstation.

[0050] As used herein, the term “electromagnet” includes any arrangement whereby a magnetic field is generated under certain electrical conditions. Typically, such arrangement includes a wire coil (typically copper wire) which, when an electrical current is passed through the wire, generates a magnetic field passing through and out of the coil. A greater number of turns in the coil provides a field of greater strength. In many cases an electromagnet will include a core, with the wire wound around the core. The function of the core may be to concentrate the magnetic field generated by the wire coil. The core may be a magnetizable metal, and may be ferromagnetic. When electrical current is applied to the wire the metal core may temporarily function as a magnet. When the current is halted, the metal ceases to function as a magnet.

[0051] The electromagnet is preferably not of excessive magnetic strength, so as to limit power consumption. Power consumption of an electromagnet is dictated by the resistance of the wire coil, and accordingly a coil formed from a shorter length of wire will have less overall electrical resistance. The length of wire may be chosen so as to provide an electromagnet of sufficient strength to counteract a lifting force of a robotic gripper.

[0052] In some embodiments, the magnetic field strength is adjustable by way of pulse width modulated power supply. The duty cycle of the pulse may be adjusted to fine tune magnetic field strength to be sufficient in the context of the application, whilst not consuming excessive power.

[0053] The electromagnet may act on the sample container holder directly, or may act on a carrier associated with a sample container holder. In either case the electromagnet acts on a magnetically active substance of the holder or the carrier. The magnetic activity may rely on magnetism (including paramagnetism) and accordingly the material may be magnetic or paramagnetic. The material may ferromagnetic, given the preference for a robust magnetic attraction using readily available materials. Exemplary materials include iron, nickel , cobalt and their alloys. Alloys with non-metallic materials such as Alnico (i.e. aluminum, nickel and cobalt), and ceramic materials such as ferrite may be useful.

[0054] The entire sample container holder or carrier may be fabricated wholly or predominantly from a magnetically active material. For reasons of weight and economy, the sample container holder or the sample container holder carrier may be fabricated from a plastic, with a magnetically active material formed into a discrete structure which is attached or incorporated into the plastic. As one example a steel plate may adhered to, or clipped to, a bottom face of a plastic container holder or sample container holder carrier. In another example a steel screw having a large head is countersunk to the bottom face of the plastic holder or carrier. A further alternative is to incorporate a steel bar during molding of a plastic sample container holder or sample containerholder carrier. In some embodiments, the sample container holder carrier is configured as a shallow tray, and in some circumstances the trav may be formed completely or predominantly from a magnetically active metal, such as stainless steel.

[0055] In some embodiments, a magnetically active material is distributed throughout the sample container holder or the sample container carrier so as to confer magnetic activity on the structure as a whole. In an exemplary form, a liquid monomer is mixed with iron particles, and the mixture polymerized to form a magnetically active sample container holder or sample container holder carrier.

[0056] In the context of the disclosure, the term “sample container holder” includes any means for releasably holding a plurality of sample containers, preferably sample containers used to hold a sample for analysis in an automated sample handling system of an analytical laboratory. Each sample container may be disposed in a separate cavity or space of the holder, and may be removed by a substantially vertical movement. Generally sample containers are held in a line, a grid, an array, or some other regular arrangement. Typically a sample container holder is dedicated to the purpose of holding sample containers. A sample container holder may not be a part of any item of laboratory equipment, or be an adapter allowing for multi-apparatus use, or any other contrivance that may otherwise be capable of, or used for, holding sample containers.

[0057] A sample container holder may be of substantially solid constructed and in the form of a block having cavities formed therein. Alternatively, it may be a tray having upwardly extending fingers with a sample container being retained upright between two or more fingers. As another option, the rack may be fabricated from wire, and therefore be of a generally open construction.

[0058] A sample container holder may be configured to hold at least about 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, or 24 sample containers.

[0059] A sample container holder may be configured to hold very small containers such as reaction tubes of milliliter capacity, slender test tubes having a capacity of 10-15 mL, and higher capacity tubes of more squat proportions such as 50 mL tubes. The containers may be primary tubes such as those used in pathology sample collection such as blood tubes, sputum jars, urine jars; PCR tubes; or secondary containers used for sample storage, sample aliqotting. A container may be compatible for use with a certain item of laboratory equipment such as a biochemistry analysis machine.

[0060] As used herein, the term “sample container holder carrier” includes any contrivance that is capable of carrying a sample container holder. Typically, the sample container holder carrier includes a portion for contacting a surface of sample container holder, and some means of preventing lateral movement of the sample container holder relative to that portion. In exemplary form, the sample container holder carrier comprises a floor portion upon which the sample container holder may be disposed, and one or more walls extending upwardly from the floor portion so as to prevent lateral movement of sample container holder relative to the floor portion.

[0061] As indicated supra, the electromagnet may act on a carrier of a sample container holder, rather than the sample container holder itself. In such embodiments, the carrier is magnetically active so as to be attracted to the plurality of electromagnets.

[0062] The sample container holder carrier and / or the sample container holder is / are configured so as to remain coupled and remain in position on the surface should a tube which is jammed in the sample container holder be lifted by the robotic gripper. Preferably the carrier and the holder are reversibly coupled.

[0063] A suitable coupling may be achieved where both holder and carrier are magnetically active, with the electromagnet of the apparatus acting on both holder and carrier so as to constrain both articles to the surface of the apparatus. Alternatively, a mechanical coupling may be used, such asa ledge formed by the carrier with the holder being slid under the ledge. In this embodiment, an upward force on the holder is transferred to the carrier. Given that the carrier is retained on the surface by the electromagnet, the holder is prevented from becoming airborne.

[0064] As a further example of a mechanical coupling, the carrier may comprise a hinged arm which is manually swung over the holder, so as to prevent lifting of the holder from the carrier. The arm may be swung back to the first position as required to release the holder from the carrier.

[0065] The present apparatus may be configured as a benchtop workstation, and in such cases a power supply of modest capacity is typically incorporated. Any significant current load placed on the circuits of the workstation by the electromagnets may destabilize the voltage output by the power supply. Fluctuations in voltage or insufficient voltage can negatively affect sensitive components of the apparatus such as processors, controllers, microcontrollers, electronic memory, stepper motors and the like leading to malfunction of the workstation.

[0066] Even without the possibility of malfunction, it is generally desirable to limit power consumption in a workstation. In a laboratory processing large numbers of samples, a workstation may be operating for extended period of time around the clock.

[0067] Accordingly, the apparatus may be configured such that the electromagnet is activated (i.e a voltage applied to the coil wire) only when necessary. For example, the apparatus may have five sample container holders on the surface, with the robotic gripper capable of lifting a sample container from any one of the five sample container holders. An electromagnet underlies each of the five sample container holders, with each of the electromagnets being independently operable. Where the robotic gripper is operating so as lift a container from one of the five holders, the electromagnet underlying that holder only is activated so as to attract the holder. The electromagnets underlying the remaining four sample container holders (which are not liable to any lifting force) are not activated so as to conserve power.

[0068] In addition or alternatively, an electromagnet may be activated only when the robotic gripper is in the process of lifting a sample container. Thus, the electromagnet remains deactivated for the time that the robotic gripper is travelling toward the sample container to be lifted (i. e. lateral travel in the x-, or y-direction), during the time period that the robotic gripper is lowered toward the container (i.e. downward vertical travel in the z-direction), and also when the robotic gripper is travelling away from the container position after having lifted the sample container (i.e. lateral travel in the x- or y-direction).In some embodiments, the electromagnet is activated without any reference to x-position, y- position or lifting activity of the robotic gripper. In such embodiments, the electromagnet may be activated only where some unexpected resistance to lifting is detected. An expected resistance would be that within the normal range of resistances as occasioned by the weight of an expected sample container holding an expected maximum sample. Any resistance higher than the normal range would indicate that the gripper is attempting to lift not only the sample container, but also the sample container holder. In that case, the electromagnet could be instantly activated to attract the sample container holder on the surface. Even where the sample container actually lifts from the surface, an electromagnet of sufficient force could Thus, an electromagnet may never be activated so long as the apparatus does not encounter a jammed sample container.

[0069] An unexpected resistance to lifting may be indicated by, for example, a strain gauge or a load cell mounted in series with the robotic gripper. Alternatively, an excessive current drawn by a stepper motor used to lift the robotic gripper may indicate an unexpected resistance to lifting. In an event, a detected unexpected resistance is indicative that the sample container is jammed in its holder, and the holder is, or will be, lifted unless some action is taken by the apparatus.

[0070] In some embodiments, the selective activation of electromagnets is governed by a processor / controller of the apparatus. The apparatus is typically user-programmable such that therobotic gripper executes a defined series of movements, as required for an given task. Such movements may be selected from an electronic touch screen user interface. For example, the user may select a program which instructs the stepper to move a container from a certain position in first sample container holder to a certain position in a second sample container holder. The program has reference to x,y coordinates for first and second sample container holders, and also coordinates for the certain positions within the first and second holders. Accordingly, a program instruction to lift the sample container from the first sample container holder may instruct the operating system to also activate the electromagnet under the first sample container holder. No such instruction is made to activate the electromagnet under the second sample container holder, and that electromagnet therefore remains deactivated.

[0071] In other embodiments the presence of a sample container holder above an electromagnet is detected, with an electromagnet being activated only where a sample container holder is detected. An apparatus may have five electromagnets, with sample container holders being detected only over two electromagnets. In that circumstance, only two electromagnets are activated, thereby saving the need to power the three remaining electromagnets. While that approach leads to some wastage of power (because it is never the case that both sample container holders are vulnerable to lifting), a power saving nevertheless presents.

[0072] Detection of a sample container holder may be by way of a hall effect sensor, a light sensor, or a capacitive sensor. Alternatively, disposition of a magnetically active sample container holder over the electromagnet may generate a small current in the electromagnet coil, the current being detectable by the operating system.

[0073] An electromagnet may function to retain the sample container holder on the surface while the robotic gripper continues to attempt lifting the sample container upwardly. Where the sample container is jammed to only a slight extent, the lifting force of the robotic gripper may be sufficient to free the sample container from its holder, and the apparatus can continue operating normally.Where several seconds have elapsed and the robotic gripper has not moved upwardly into its highest position in the z-direction, it may be inferred that the sample container has not been freed, and the apparatus function halted and an error signal issued by the operating system to trigger manual correction by a human.

[0074] Any teaching above in relation to the sample container holder may apply also to a sample container holder carrier.

[0075] The sample container holder carrier may be magnetically active by any of the means discussed supra for the sample container holder. In such embodiments the sample container holder may be magnetically inactive, and may be fabricated from a plastic material. In other embodiments, the sample container holder carrier is magnetically inactive, with the electromagnets acting on a magnetic active sample container holder carried by the carrier. In some cases, the carrier allows contact or near contact of the sample container holder with the surface, thereby allowing the electromagnetic field to retain both components on the surface.

[0076] The apparatus may comprise one or arranging elements configured to position and / or aligning and / or orient the sample container holder and / or the sample container holder carrier on the surface. As discussed supra, the robotic gripper may move in accordance with program steps having regard to x and y coordinates. Those coordinates will only be valid where the sample containers are in an expected position (i.e. have expected x and y coordinates). The sample containers can only be in their respective expected positions where the sample container holder is in an expected position on the surface. An arranging element may function to ensure that the holder is disposed on the surface in the expected position. The alignment or orientation may be with reference to an axis of the surface, an edge of the surface, or an axis along which the robotic gripper is movable. The positioning may be with reference to x and y coordinates of the surface.

[0077] The arranging element is typically configured to assume a fixed alignment and / or orientation. Accordingly, the element may be mounted or mountable on or about the surface in only a single alignment of orientation. For example, the arranging element may be of linear construction and mounted or mountable directly across the surface, so as to be orthogonal to a long edge of the surface.In some embodiments, the arranging element is comprised of two elongate discrete linear components which flank the sample container holder. In other embodiments the arranging element is unitary.

[0078] As discussed supra, the sample container holder carrier may engage with the sample container holder such that any lifting force of the holder (by way of a jammed sample container) is transferred to the carrier. Such engagement is not required where the sample container holder is itself magnetically active and is therefore retainable on the surface by the electromagnet.

[0079] The surface of the apparatus is typically planar, performing the general function of supporting the sample container holder. The support may be direct (the sample container holder sits on and contacts the surface), or indirect (the sample container holder being supported by the sample container holder carrier and / or the arranging element.

[0080] The surface is typically provided by the upper surface of a tray-like structure of the apparatus. The tray may be fabricated from a rigid plastic sheet having a thickness that allows a magnetic field generated by an electromagnet on the underside to attract a magnetically active object on the upper side. Alternatively, the tray may be fabricated from a magnetically active material which itself becomes temporarily magnetized under the influence of an underlying electromagnet.

[0081] In some embodiments, the tray comprises apertures or recesses to allow the surfaces of the electromagnets to sit flush with, or slightly proud of, or slightly beneath the tray upper surface.

[0082] By way of further description, reference is now made to the following non-limiting embodiments illustrated in the drawings.

[0083] FIG. 1 illustrates a preferred embodiment of the present apparatus (10). The apparatus (10) comprises a tray (15) having three areas (20a, 20b, 20c) in which a sample container holder (not drawn) may sit. Beneath the tray (15) surface are the electromagnets (25a, 25b, and 25c) each in register respectively with the areas (20a, 20b, 20c). The electromagnets (25a, 25b, and 25c) are each capable of generating a magnetic field of sufficient strength so as to extend above the tray (15) surface so as to attract a magnetically active item sitting in the area above.

[0084] A controller / processor (30) is in wired electrical connection with each of the electromagnets (25a, 25b, and 25c). The controller / processor comprises independent outputs for each of the electromagnets (25a, 25b, and 25 c) such that any given electromagnet can be independently activated or deactivated.

[0085] The apparatus (10) comprises a user interface (35) being a touch screen presenting various menus to the user and configured to accept touch input. The user interface is in duplex data communication with the processor / controller (30) such that menus are displayed in accordance with program instructions stored in electronic memory (32) accessible by the processor / controller (30), and user input is provided to the processor / controller (30) and in turn as input to the program instructions.

[0086] The processor / controller (30) is in duplex data communication with the robotic gripper (40), such that instructions from the processor / controller as generated by program instructions causes movement of the robotic gripper (40) laterally across the tray (15) in the x- and y-dir ections so as to locate over the x,y coordinate of a sample container. The program instructions also cause vertical movement of the robotic gripper (40) in the z-direction so as to lower onto a desired samplecontainer, and to lift that container vertically upwardly. Once in the fully upward position, the processor / controller (30) instructs the robotic gripper (40) to mover laterally to a desired location, where the sample container is lowered. The robotic gripper (40) provides output to the processor controller (30) to report parameters such as x,y,z position.

[0087] In the starting configuration of the apparatus, each of the electromagnets (25a, 25b, and 25 c) is deactivated so as to conserve power.

[0088] The user selects a menu item by way of user interface (35) to move a sample container from a sample container holder disposed in area (20a) to an empty sample container holder disposed in area (20b). In response, the robotic gripper moves in the x- and y-directions so as to locate over the sample container. The robotic gripper (40) is lowered onto the sample container so as to tightly engage therewith. The x,y,z position is reported to the processor / controller (30) with the program instructions triggering a lifting instruction to the robotic gripper (40), and at the same time applying voltage of the electromagnet (25a). The electromagnet (25a) generates a magnetic field to attract the sample container holder (which is magnetically active). Electromagnets (25b, 25c) are not activated to save power. There is no sample container holder in area (25c), and the holder in area (25b) is not subject to inadvertent lifting as it does not hold any sample container.

[0089] Where the sample container in area (25a) is freely lifted from its holder, the action of the electromagnet (25a) is redundant given the lack of any possibility that the sample container holder was inadvertently lifted. However, where the sample container is jammed in its holder the attraction of the electromagnet prevents lifting of the sample container holder in area (25a). Continued upward force applied by the robotic gripper (40) may be sufficient to free the sample container from its holder, and in which case the apparatus continues to execute the user program of robotic gripper (movements). Where the sample container is unable to be freed (that being detected by failure of the robotic gripper (40) to achieve its most upward z-location within 3 secs,as assessed by the program instructions), the processor / controller (30) cuts power to the robot gripper (40), and an error message is shown on the user interface, along with an alarm sound to alert a human operator. The operator may dislodge the sample container from its tube, reset the apparatus (10) via user interface (35) are restart the program

[0090] The selective powering only of electromagnet (25a) saved a first quantity of power (that quantity being the combined power requirements of electromagnets (25b) and (25c). The selective powering of electromagnet (25a) only for the period that robotic gripper (40) is lifting vertically saved a second quantity of power (that quantity being the power requirement of electromagnet (25a) for the period that the robot gripper (40) is travelling laterally to the sample location and lowering onto the sample container.

[0091] Reference is now made to FIG. 2 illustrating a more basic version of the embodiment of FIG. 1. In FIG. 2, the presence or absence of a sample container holder is sensed by sensors (45a, 45b, 45c), with there being requirement for any user menu selection to identify the area (20a, 20b, or 20c) where the source sample container is located. In this example, the sample container holder is in area 20a, with the sample container being moved by the robotic gripper (20) to an empty sample container holder in area (20b). Power is applied to electromagnets (25a) and (25b). Activation of electromagnet (25b) is redundant because the sample container holder in area (20b) is not liable to be lifted by the robotic gripper (40). Nevertheless, a quantity of power is saved, that quantity being the power that would have otherwise been consumed by electromagnet (25c). In this embodiment, there is no power saved by the selective timing of power application to electromagnet (25a), as was the case for the embodiment of FIG. 1.

[0092] Reference is now made to FIG. 3, showing an apparatus (10) functioning similarly to that illustrated in FIG. 1. The apparatus (10) of FIG. 3 is configured as a bench-top workstation for use in an analytical laboratory for the purpose of sorting tubes. Disposed beneath the tray (15) are a series of electromagnets (25a to 25f) that are selectively activated and deactivated by theprocessor / controller (30) in accordance with program instructions stored in electronic memory (32). A touchscreen user interface (35) is provided for display of menus and user selection thereof.

[0093] Also illustrated in FIG. 3, is a conventional tube rack (100) being plastic molded and therefore magnetically inactive. The tube rack (100) holds a plurality of sample tubes (105) in a conventional manner. The robotic gripper (40) is movable in the x- and y-directions so as to locate any one of the tubes (105) in the rack (100). The robotic gripper (40) is also movable in the z- direction, and can be lowered onto a tube, engage the tube, and lift the tube upwardly for subsequent transport to another area of the tray (15).

[0094] The tube rack (100) is disposed in a tube rack carrier (200) which is fabricated at least in part from a magnetically active material. As such, the tube rack carrier (200) can be attracted to the tray upon activation of the electromagnet (25b), as required, for example when the robotic gripper (40) is lifting a tube (105) so as to prevent lifting of the tube rack (100). In that regard, it will be appreciated that the tube rack carrier (200) engages the tube rack (100) such that retention of the tube rack carrier (200) on the tray by attraction of electromagnet (25b) also retains the tube rack (100) so as to prevent lifting of the tube rack carrier (200) should the tube (105) being lifted become jammed in its rack (100).

[0095] FIG. 3 illustrates also the rack fences (300a) and (330b) each of which is fixable onto the tray (15) in a required position. The rack fences (330a, 300b) aligns and positions the tube rack carrier (200), and therefore the tube rack (100), such that the tubes (100) are each in an expected position (i.e. an expected x,y position) such that the robotic gripper (40) is able to move to that expected position and lift the required tube (100). As will be appreciated, the robotic gripper (40) is typically movable to only discrete x,y positions, and accordingly each of the tubes (100) should be located at one of those discrete x.y positions. Each of the discrete x,y positions in turn correlates to an x,y position addressed by the program instructions, which in turn correlates to a position according to a particular program of tube movements selectable by a user.

[0096] Further description is now provided in relation to the tube rack carrier (200) and the rack fences (300a, 300b), with reference now made FIG. 4. At first instance, the rack fences (300a, 300b) are fixed by the user at a required location on the tray (15), and separated by a distance in accordance with the tube rack to be received. A tube rack carrier (200) carrying a tube rack (100) is slid laterally onto rack fences (300a, 300b) by the user. The direction of sliding is into the page.

[0097] Each of the rack fences (300a, 300b) has a ramp (305a, 305b) on its upper face at the near edge. The ramps (305a, 305b) have short upwardly extending wall at their outer edges. The ramps (305a, 305b) and walls function to center the tube rack carrier (200) as its end portion is firstly placed onto the ramps (305a, 305b). The user slides the tube rack carrier (200) toward the back of rack fences (300a, 300b) with the end of the tube rack carrier (200) moving downwardly, and into space defined between the rack fences (300a, 300b). The remainder of the tube rack carrier (200) follows, with the entire structure eventually seating in the space. It will be noted that a shallow ledge extends from ramps (305a, 305b) to provide a sliding surface for the tube rack carrier (200). The ledge forms a stop at the far end of the rack fences (300a, 300b) to prevent any further sliding movement.

[0098] Each of the rack fences (300a, 300b) comprises two sets of sensors (such as Hall sensors) that are activated when aligned with a trigger feature (such as a permanent magnet) on the tube rack carrier (200). The sensors and permanent magnets are positioned such that the sensors will not activate (or will activate) in the event the tube rack carrier (200) is installed in the wrong orientation (180 degrees). The sensors are also intended to signal to the apparatus (10) operating system that the tube rack carrier (200) has been installed correctly by the user, and is not partially seated on the tray (15). In the event a particular electromagnet (25) is not sufficiently powerful to hold a tube rack carrier (200) down during operation, and the robotic gripper (40) lifts the tube rack carrier (200), the sensors will trigger an error.

[0099] Conventional workstations use a micro switch to signal that a rack has been loaded correctly. The rack retention also requires horizontal compression from a spring to hold the rack in place. There is no fault detection in that approach.

[0100] Conventional fault detection mechanisms are typically less compatible with automated systems. Loading the racks is intuitive after a few attempts and after the operator has been trained. The present disclosures allows the operator to a drop a rack carrier onto the arranging elements and the rack carrier automatically seats in the correct position. Barcodes and Aruco alignment features located on the rear of the rack carrier may assist an imaging system of the apparats to identify which rack is loaded and the rack which is present on the rack carrier. Cutouts may be placed on the rack carrier to allow the imaging system check if a rack has been installed on a rack carrier or not.

[0101] In some embodiments of the apparatus, the circuit used to power the electromagnets is monitored by a current sensing IC. This is a fault detection feature that signals when an electromagnet is not functioning properly by means of an open circuit failure. This is a common failure mode for electromagnets as the entire circuit including the cable is being tested continuously. If a connector, PCBA, power supply, electromagnet or controlling circuit element fails then this will be detected and reported to the operating system.

[0102] The present disclosure may be embodied in the form of program instructions executable by a processor of the present apparatus. The instructions may take the form of software or firmware or both. The program instructions may be configured to execute any method disclosed herein, including any steps of inputting information relating to a position of a sample container holder or a sample container holder carrier on the apparatus surface, triggering application of current to a selected electromagnet based on the positional information and / or operating state of the robotic gripper, halting current application to an electromagnet based on the operating state of the robotic gripper some error detection system. The program instructions may be stored on aphysical medium such as solid state storage means, magnetic storage means, or optical storage means.

[0103] It should be understood that the foregoing description is only illustrative of the aspects of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the aspects of the present disclosure. Accordingly, the aspects of the present disclosure are intended to embrace all such alternatives, modifications and variances that fall within the scope of any claims appended hereto. Further, the mere fact that different features are recited in mutually different dependent or independent claims does not indicate that a combination of these features cannot be advantageously used, such a combination remaining within the scope of the aspects of the present disclosure.

[0104] Any single feature or combination of features described herein may be implemented not only with the preferred embodiments disclosed herein, but also any other embodiment falling within the ambit of the present disclosure.

Claims

CLAIMS:

1. An apparatus for handling a sample container, the apparatus comprising: a surface for supporting (i) a magnetically active sample container holder or (ii) a magnetically active sample container holder carrier, a robotic gripper configured to lift a sample container from a sample container holder supported by the surface, a plurality of electromagnets disposed about the support surface, and a controller / processor configured to selectively activate one or more of the plurality of electromagnets, wherein activation of one or more of the plurality of electromagnets attracts the sample container holder or the sample container holder carrier toward the surface.

2. The apparatus of claim 1, wherein the electromagnetic attraction is at least sufficient to resist a lifting force of the robotic griper.

3. The apparatus of claim 1 or claim 2, wherein the controller / processor is configured to input locational information in relation to a sample container holder or a sample container holder carrier about the surface, and depending on the input locational information selectively activate one or more of the plurality of electromagnets.

4. The apparatus of any one of claims 1 to 3, wherein the controller / processor activates one or more of the plurality of electromagnets for at least the period of time that the robotic gripper lifts a sample container from a sample container holder about the surface, and deactivates the activated one or more of the plurality of electromagnets when the lifting ceases, or within 10 sec, 30 sec, 1 min, 2 min, 3 min, 4 min, 5 min, 6 min, 7 min, 8 min, min or 10 min after lifting ceases.

5. The apparatus of any one of claims 1 to 4, wherein the one or more plurality of electromagnets are flush with the surface, or disposed below the surface, or are proud of the surface at a height of less than about 5 mm, 4 mm, 3 mm, 2 mm, 1 mm or 0.1 mm.

6. The apparatus of any one of claims 1 to 5, wherein the surface is provided by a tray configured in terms of material and / or thickness to allow at least about 50%, 50%, 70%, 80%,90% or 95% of the magnetic field strength generated by the plurality of electromagnets to act on a sample container holder or a sample container holder carrier about the surface.

7. The apparatus of any one of claims 1 to 6, wherein the plurality of electromagnets are disposed substantially regularly across the surface.

8. The apparatus of ant one of claims 1 to 7, wherein the plurality of electromagnets comprises at least or about 3, 4, 5, 6, 7, 8, 9 or 10 electromagnets.

9. The apparatus of any one of claims 1 to 8, wherein a sample container about the surface is configured to retain a plurality of sample tubes, each sample tube having a diameter between about 10 mm and about 25 mm.

10. The apparatus of any one of claims 1 to 9 comprising one or more arranging elements configured to alignment and / or position and / or orient a sample container holder and / or the sample container holder carrier with reference to an axis of the surface.

11. The apparatus of claim 10, wherein the surface is generally rectangular and the axis is a short axis.

12. The apparatus of claim 10 or claim 11, wherein the one or more arranging elements presents a space into which a sample container holder, or a sample container holder carrier, is locatable within.

13. The apparatus of claim 12, wherein the one or more arranging elements present a ramp running downwardly to the space.

14. The apparatus of any one of claims 1 to 13, wherein the one or more arranging elements are configured to locate a sample container holder, or a sample container holder carrier, in a x, y-location across the surface, and optionally a z-location above the surface.

15. The apparatus of any one of claims 10 to 14, wherein the one or more arranging elements, and / or a sample container holder, and / or a sample container holder carrier is / areconfigured so as to allow contact between the surface and the sample container holder, or the sample container holder carrier.

16. The apparatus of any one of claims 10 to 15, wherein the one or more arranging elements are releasably engageable with the apparatus so as to be locatable about the surface.

17. The apparatus of any one of claims 10 to 16, wherein the one or more arranging elements is each comprised of paired parallel members mutually spaced so as to allow a sample container holder, or a sample container holder carrier to sit thereon and / or therebetween.

18. The apparatus of any one of claims 1 to 17, configured as a floor-standing or bench- top workstation for robotically handling sample containers having a capacity of between about 1 mL and about 50 mL, the handling forming part of a sample handling workflow in an analytical laboratory.

19. A system comprising: the apparatus of any one of claims 1 to 18, a sample container holder optionally carrier by a sample container holder carrier, and a sample container disposed in the sample container holder, wherein the system is configured such that lifting of a sample container that is jammed in the sample container holder by the robotic gripper is prevented by one or more of the plurality of electromagnets.

20. The system of claim 19, wherein the sample container holder and the sample container holder carrier are mutually engaged such that a lifting force applied to a sample container jammed in the sample container holder is transferred to the sample container holder carrier.

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