Vacuum-operated systems and methods for handling objects

Abstract

A vacuum-operated object-handling apparatus includes a vacuum module and an object-handling member configured to move at least in a vertical direction. The object-handling member defines a lumen extending from a first end portion to a second end portion. The first end portion is fluidly connected to the vacuum module, and the second end portion is open to air. The vacuum module is configured to create a pressure differential between the lumen and the air, and a gauge sensor is configured to determine the gauge pressure at a test location within the lumen. Further, the vacuum-operated object-handling apparatus includes an apparatus controller configured to execute the continuous motion of the object-handling member at least in the vertical direction towards an object and execute a soft stop of the continuous motion when a change in the gauge pressure is below a threshold.

Description

[0001] Patent Application 003168.4560

[0002] VACUUM-OPERATED SYSTEMS AND METHODS FOR HANDLING OBJECTS

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004] The application claims priority to U.S. Provisional Application No. 63 / 712,691, filed October 28, 2024, the contents of which is incorporated herein by reference in its entirety.

[0005] BACKGROUND

[0006] This disclosure relates to certain vacuum-operated systems and methods for handling objects.

[0007] Vacuum pickers use suction for secure gripping and are widely used for their versatility in handling diverse objects. Several methods have been used to pick and place disposable plastic parts (which can be called consumables) in processing Nucleic Acid Tests (NAT). Operations can include loading pre-oriented trays of each consumable type, transporting these consumables to a consumable loader mechanism, and then picking the consumable from the tray and placing it into a point of use location such as a carousel or processing track.

[0008] Existing methods of consumable loading include mechanical grippers, mechanical friction fit (staking), and vacuum pickers. These methods can involve calibrating the pick location to account for variability in instrument operations and the consumable trays or stacks of consumables. In the event of a missed pick operation, subsequent attempts can involve various “hunt and peck” movements to successfully pick the consumable. However, these attempts can forcibly disrupt the positioning and alignment of adjacent consumables, resulting in multiple losses of viable testing consumables and potential damage to the vacuum picker.

[0009] Further, certain vacuum pickers face challenges in high-precision tasks. Inadvertent bumping due to misalignment or control system limitations can damage both the picker and the object. Additionally, limitations in reach or data inaccuracies can hinder precise grasping, leading to inefficient handling and potential drops. Addressing these issues of bumping and imprecise reaching can be crucial for boosting vacuum picker reliability and efficiency. Therefore, advancements in precision and control mechanisms are necessary for ensuring accurate and safe object handling. Patent Application 003168.4560

[0010] SUMMARY

[0011] In accordance with the disclosed subject matter, vacuum-operated object-handling apparatus, methods, and systems are disclosed herein.

[0012] In accordance with the disclosed subject matter, a vacuum-operated object-handling apparatus is provided. An example vacuum-operated object-handling apparatus includes a vacuum module, an object-handling member configured to move at least in a vertical direction and defining a lumen extending from a first end portion to a second end portion thereof, wherein the first end portion is fluidly connected to the vacuum module and the second end portion is open to air. The vacuum module is configured to create a pressure differential between the lumen and the air. Further, the vacuum-operated object-handling apparatus includes a gauge sensor operatively coupled to the object-handling member and configured to determine a gauge pressure at a test location within the lumen and an apparatus controller. The apparatus controller is operatively coupled to the object-handling member and to the gauge sensor and is configured to execute a continuous motion of the object-handling member in at least in the vertical direction towards an object and to execute a soft stop of the continuous motion when a change in the gauge pressure is below a threshold.

[0013] In accordance with the disclosed subject matter, the apparatus controller is further configured to monitor, at a set frequency, the change in the gauge pressure.

[0014] In accordance with the disclosed subject matter, the object-handling member is further configured to move in a lateral direction perpendicular to the vertical direction.

[0015] In accordance with the disclosed subject matter, the vacuum-operated object-handling apparatus is further configured to move the object from a first location to a second location by executing a motion of the object-handling member in the vertical direction, the lateral direction, or a combination thereof and release the object from the object-handling member at the second location by venting the lumen, thereby setting the gauge pressure to about zero or a positive value.

[0016] In accordance with the disclosed subject matter, the object-handling member includes a vacuum end effector comprising a flexible material.

[0017] In accordance with the disclosed subject matter, the vacuum end effector is formed from a material consisting of silicon elastomer, rubber, plastic, or a combination thereof.

[0018] In accordance with the disclosed subject matter, the vacuum end effector includes a flat surface containing one or more holes. The one or more holes fluidly connect the lumen with the air surrounding the object-handling member. Patent Application 003168.4560

[0019] In accordance with the disclosed subject matter, the vacuum-operated object-handling apparatus further includes a coupling configured to couple a connecting member of the objecthandling member and any one of a set of vacuum end effectors, each one of the set of vacuum end effectors configured to attach to objects being handled.

[0020] In accordance with the disclosed subject matter, the set of vacuum end effectors includes a cylindrical shape configured to be inserted into an opening of a consumable, such that there is a sufficient seal between the walls of the consumable and the cylindrical shape for maintaining a required negative gauge pressure within the consumable.

[0021] In accordance with the disclosed subject matter, the apparatus controller is further configured to compute a running average of the gauge pressure over a first predetermined time window and compute the change in the gauge pressure by computing the change in the running average over a second predetermined time window.

[0022] In accordance with the disclosed subject matter, the first predetermined time window is about ten milliseconds.

[0023] In accordance with the disclosed subject matter, the soft stop includes performing a deceleration of the object-handling member by utilizing a prescribed deceleration profile characterizing a reduction of the velocity of motion of the object-handling member as a function of time.

[0024] In accordance with the disclosed subject matter, the prescribed deceleration profile is one of linear, quadratic or exponential.

[0025] In accordance with the disclosed subject matter, the vacuum module includes a negative pressure-generating device, a positive pressure-generating device, and a valve system having at least a first configuration and a second configuration. The valve system, in the first configuration, is arranged to fluidly connect the lumen with the negative pressure-generating device, and in the second configuration, it is arranged to fluidly connect the lumen with the positive pressure-generating device, such that when the valve system is in the first configuration, a negative gauge pressure is created in the lumen by operating the negative pressure-generating device, and when the valve system is in the second configuration, a positive gauge pressure is created in the lumen by operating the positive pressure-generating device.

[0026] In accordance with the disclosed subject matter, the vacuum module further includes a negative pressure chamber being maintained at a negative gauge pressure by fluidly connecting Patent Application 003168.4560 the negative pressure-generating device to the negative pressure chamber, wherein the vacuum chamber can be configured to fluidly connect to the lumen.

[0027] In accordance with the disclosed subject matter, the apparatus controller is configured to fluidly couple the negative pressure chamber to the lumen when the negative pressuregenerating device is disabled.

[0028] In accordance with the disclosed subject matter, the valve system can also be placed in a third configuration, such that, when the valve system is in the third configuration, the lumen is fluidly coupled to the negative pressure chamber.

[0029] In accordance with the disclosed subject matter, the vacuum module further comprises a positive pressure chamber being maintained at a positive gauge pressure by fluidly connecting the positive pressure-generating device to the positive pressure chamber, wherein the positive pressure chamber can be configured to fluidly connect to the lumen.

[0030] In accordance with the disclosed subject matter, the valve system can also be placed in a fourth configuration, such that, when the valve system is in the fourth configuration, the lumen is fluidly coupled to the positive pressure chamber.

[0031] In accordance with the disclosed subject matter, the apparatus controller and FPGA are further configured to determine the change in the gauge pressure as the object-handling member executes the continuous motion toward the object.

[0032] In accordance with the disclosed subject matter, the lumen of the object-handling member is fluidly connected to the vacuum module via a flexible channel configured to fluidly connect the lumen and the vacuum module, for different vertical and lateral positions of the object-handling member relative to the vacuum module. Further, in accordance with the disclosed subject matter, the vacuum module can include a negative pressure-generating device, a positive pressure-generating device, and a valve system. Further, the flexible channel can be arranged to connect the lumen to the valve system. Further, the valve system is operable to couple the object-handling member to the positive pressure-generating device when the valve system is in a first configuration and couple the object-handling member to the negative pressure-generating device when the valve system is in a second configuration.

[0033] In accordance with the disclosed subject matter, systems for handling objects are disclosed. An example system includes a tray that is configured to contain at least one object. The tray is configured to move at least along a straight line in a first lateral direction. Further, the system includes a vacuum-operated object-handling apparatus. The vacuum-operated object-handling apparatus includes a vacuum module and an object-handling member Patent Application 003168.4560 configured to move at least in a vertical direction. The obj ect-handling member defines a lumen extending from a first end portion to a second end portion, wherein the first end portion is fluidly connected to the vacuum module, and the second end portion is open to air. Further, the vacuum module is configured to create a pressure differential between the lumen and the air. The vacuum-operated object-handling apparatus further includes a gauge sensor that is operatively coupled to the object-handling member and is configured to determine a gauge pressure at a test location within the lumen and an apparatus controller. The apparatus controller is operatively coupled to the object-handling member and to the gauge sensor and is configured to execute a continuous motion of the object-handling member, at least in the vertical direction towards an object, and execute a soft stop of the continuous motion when a change in the gauge pressure is below7a threshold.

[0034] In accordance with the disclosed subject matter, the object-handling member is further configured to move in a second lateral direction perpendicular to the vertical direction and the first lateral direction. The system further comprises a system controller configured to determine a lateral coordinate position at which the object is located, move the tray in the first lateral direction by a first distance, the first distance being selected such that the object is located at the lateral coordinate position, and move the object-handling member in the second lateral direction by a second distance, the second distance being selected such that the object-handling member is placed directly above the lateral coordinate position.

[0035] In accordance with the disclosed subject matter, the first distance and the second distance are determined by the system controller, and wherein the system controller is configured to communicate the second distance to the apparatus controller.

[0036] In accordance with the disclosed subject matter, the object-handling member includes a connecting member coupled to a vacuum end effector via an end effector coupling, and wherein the vacuum end effector is selected from a set of vacuum end effectors, each one of the set of vacuum end effectors configured to handle a particular object from a set of objects.

[0037] In accordance with the disclosed subject matter, the set of objects comprises tubular objects, tip objects, and tray objects.

[0038] In accordance with the disclosed subject matter, the apparatus controller is further configured to automatically decouple the vacuum end effector via the end effector coupling and automatically couple the vacuum end effector via the end effector coupling.

[0039] In accordance with the disclosed subject matter, the end effector coupling includes a magnetic coupling using an electromagnet. Patent Application 003168.4560

[0040] In accordance with the disclosed subject matter, the system further includes a track extending in a second lateral direction, a track sliding device for moving along the second lateral direction, and a coupling device for coupling the object-handling member to the track sliding device.

[0041] In accordance with the disclosed subject matter, methods of operating a vacuum- operated object-handling apparatus are provided. The vacuum-operated object-handling apparatus includes an object-handling member configured to move at least in a vertical direction. The object-handling member defines a lumen extending from a first end portion to a second end portion open to air. The method includes applying a vacuum to the first end portion of the lumen to thereby create a pressure differential between the lumen and the air, determining a gauge pressure at a test location within the lumen, and executing a continuous motion of the object-handling member at least in the vertical direction towards an object. Further, the method includes monitoring, at a set frequency, a change in the gauge pressure, and executing a soft stop of the continuous motion when the change in the gauge pressure is below a threshold.

[0042] BRIEF DESCRIPTION OF THE DRAWINGS

[0043] FIG. 1 illustrates an example vacuum-operated system, in accordance with the disclosed subject matter.

[0044] FIGS. 2 A and 2B illustrate examples of vacuum-operated object-handling apparatuses, in accordance with the disclosed subject matter.

[0045] FIGS. 3A-3O illustrate vacuum end effectors and their interactions with objects, in accordance with the disclosed subject matter.

[0046] FIG. 4 illustrates a schematic of a controller, in accordance with the disclosed subject matter.

[0047] FIGS. 5A-5C show example profile plots for gauge pressure, change of gauge pressure, and power supplied to a pressure generating system, respectively, in accordance with the disclosed subject matter.

[0048] FIG. 6A shows an illustrative diagram of linking a pressure generating system with an object-handling member using a valve system, in accordance with the disclosed subject matter.

[0049] FIG. 6B shows another illustrative diagram of linking various pumps of a pressure generating system with an object-handling member using vanous valves, in accordance with the disclosed subject matter.

[0050] FIG. 7 shows an illustrative method for operating a vacuum-operated object-handling apparatus, in accordance with the disclosed subject matter. Patent Application 003168.4560

[0051] FIG. 8 shows an illustrative method of moving an obj ect-handling member to a location at which an object is picked, in accordance with the disclosed subject matter.

[0052] FIG. 9 shows an illustrative method of picking an object using a vacuum-operated object-handling apparatus, in accordance with the disclosed subject matter.

[0053] FIG. 10 illustrates an example logic unit for performing the method shown in FIG. 9, in accordance with the disclosed subject matter.

[0054] DETAILED DESCRIPTION

[0055] The disclosed subject matter provides vacuum-operated object-handling apparatus, systems, and methods of operation. An example vacuum-operated object-handling apparatus includes a vacuum module, an object-handling member that can move in at least in a vertical direction, a gauge sensor and a controller. The object-handling member defines a lumen extending between first and second end portions, where the first end is fluidly connected to the vacuum module and the second end portion is open to air. The vacuum module is configured to create a pressure differential between the lumen and the air. The gauge sensor can determine a gauge pressure at a test location within the lumen. The apparatus controller implements continuous motion of the object-handling member at least in the vertical direction towards an object and can cause a soft stop of the continuous motion when the gauge pressure goes below a threshold.

[0056] Further, in accordance with the disclosed subject matter, a system for handling objects is disclosed. The system includes a tray that is configured to contain at least one object. The tray is configured to move at least along a straight line in a first lateral direction. Further, the system includes a vacuum-operated object-handling apparatus. The vacuum-operated object-handling apparatus includes a vacuum module and an object-handling member configured to move at least in a vertical direction. The obj ect-handling member defines a lumen extending from a first end portion to a second end portion, wherein the first end portion is fluidly connected to the vacuum module and the second end portion is open to air. Further, the vacuum module is configured to create a pressure differential between the lumen and the air. The vacuum-operated object-handling apparatus further includes a gauge sensor configured to determine a gauge pressure at a test location within the lumen and an apparatus controller. The apparatus controller is configured to execute a continuous motion of the object-handling member at least in the vertical direction towards an object and execute a soft stop of the continuous motion when a change in the gauge pressure is below7a threshold. Patent Application 003168.4560

[0057] Additionally, in accordance with the disclosed subject matter, a method of operating a vacuum-operated object-handling apparatus is provided. The vacuum-operated objecthandling apparatus includes a vacuum module and an object-handling member configured to move at least in a vertical direction. The object-handling member defines a lumen extending from a first end portion to a second end portion, wherein the first end portion is fluidly connected to the vacuum module and the second end portion is open to air. Further, the vacuum module is configured to create a pressure differential between the lumen and the air. The vacuum-operated object-handling apparatus further includes a gauge sensor configured to determine a gauge pressure at a test location within the lumen. The method further includes monitoring, at a set frequency, a change in the gauge pressure, executing a continuous motion of the object-handling member at least in the vertical direction towards an object, and executing a soft stop of the continuous motion when the change in the gauge pressure is below a threshold.

[0058] In the following description, for the purposes of explanation, numerous specific details are set forth to provide a thorough understanding of the present disclosure. It will be apparent, however, the disclosed subject matter can be practiced without these specific details. In other instances, well-known structures and devices are shown in schematic form to avoid unnecessarily obscuring the description of the present disclosure.

[0059] The text in conjunction with the accompanying drawings aims to articulate the designs and methods at a level of detail consistent with the communication standards among skilled individuals in the relevant arts. This level of detail mirrors the customary communication among those with expertise in the field, effectively expressing the structure and function of the various designs outlined in this disclosure.

[0060] Various features are described in this disclosure to illustrate various aspects. Other structural, logical, softw are, and other changes can be made without departing from the scope of the embodiments that are specifically described. Various modifications and alterations are possible and expected. Some features can be described with reference to one or more drawing figures, but such features are not limited to usage in the one or more figures with reference to which they are described. Thus, the present disclosure is neither a literal description of all embodiments nor a listing of features that must be present in all embodiments.

[0061] Headings of sections and the title are provided for convenience but are not intended to limit the disclosure in any way or as a basis for interpreting the claims.

[0062] A description of an embodiment with several components present does not necessarily imply that all such components are required. Optional components are described to Patent Application 003168.4560 illustrate a variety of possible configurations and to illustrate one or more aspects of the present disclosure more fully. Similarly, although processes, methods, algorithms, or the like can be described in sequential order, such processes, methods, and algorithms can generally be configured to work in different orders, unless specifically stated to the contrary. Any sequence or order described in this disclosure is not a required sequence or order. The illustration of a process in a drawing does not exclude variations and modifications, does not imply that the process or any portion thereof are necessary, and does not imply that the illustrated process is preferred. When a single device or article is described, more than one device or article can be used in place of a single device or article. Where more than one device or article is described, a single device or article can be used in place of more than one device or article.

[0063] The functionality or features of a device can be alternatively embodied by one or more other devices that are not explicitly described as having such functionality or features. Thus, other implementations need not include the device itself. Techniques and mechanisms described or referenced herein will sometimes be described in singular form for clarity. However, it should be noted that implementations include multiple iterations of a technique or multiple manifestations of a mechanism unless noted otherw ise.

[0064] Definitions

[0065] In this disclosure, terms such as “approximate,” “about,” “similar,” “equal,” “equivalent” or “the same as” are used to indicate a degree of flexibility' or tolerance in numerical values, measurements, and characteristics disclosed. The scope of the disclosure should not be limited to strict numerical precision, and these terms are employed to allow for variations within acceptable limits.

[0066] The terms “approximate,” “about,” and “similar” are used interchangeably to convey that a given value, parameter, or characteristic can deviate within a reasonable range from the stated value. This range can encompass slight variations that do not materially affect the functionality or performance of the systems and methods described in this disclosure. For example, the terms “approximate,” “about,” and “similar” can refer to a variation of ten percent from a specific value.

[0067] The terms “equal,” “equivalent,” or “the same as” are used to indicate that values, parameters, or characteristics descnbed as such are substantially identical or sufficiently close in magnitude, without necessarily requiring absolute precision. For example, such terms can refer to a deviation of a few' percent from a specific value such as one or two percent. Patent Application 003168.4560

[0068] Further, the term “similar” can be employed to denote a likeness or resemblance between two or more elements, aspects, or features, allowing for variations that do not compromise the fundamental nature or purpose of the disclosure.

[0069] In this disclosure, the term “set” is employed to denote a grouping or collection of objects, elements, components, or entities. The flexibility in the interpretation of the term “set” allows for adaptability and practical application in situations where a singular object satisfies the intended functionality7or purpose of the disclosure. Thus, the disclosure is not limited to instances where a “set” must consist of multiple objects but rather contemplates scenarios where a “set” can include one object.

[0070] Vacuum-Operated System

[0071] This disclosure uses a vacuum consumable picker and monitors the vacuum signal to determine if a consumable part has been picked. This determination is used to stop the motor movements of a vacuum picker, eliminating wasteful hunt and peck operations. Specifically, a differential vacuum level is used to interrupt motor movements, providing the most timeefficient pick operation. Additionally, this method compensates for variability in the pick location due to instrument operations and variations in the consumable trays or stacks. Furthermore, subsequent pick attempts do not forcibly nest stacked parts together, preventing the “multiple pick.”

[0072] Based on current NAT processing protocols, this disclosure describes consumable pick and place operations across multiple variants of consumable trays or stacks without the need for excessive instrument calibrations and wasteful hunt and peck operations when a consumable pick fails.

[0073] The disclosed subject matter relates to a vacuum-operated object-handling apparatus and a system containing such an apparatus. The vacuum-operated object-handling apparatus (herein sometimes referred to simply as “apparatus”) includes a vacuum module and an object-handling member configured to move in one or more directions. The object-handling member contains a lumen in which a negative gauge pressure is generated by the vacuum module. The vacuum module can be, for example, a pump that creates the negative gauge pressure. Negative gauge pressure refers to a pressure lower than atmospheric pressure, effectively creating a partial vacuum. For example, if the pressure within the lumen is Pi and atmospheric pressure is PA, then the gauge pressure is given by PI-PA. Additionally, in some cases, it is convenient to define a percentage gauge pressure (PGP) as 100X(PI-PA) / PA (%). Patent Application 003168.4560

[0074] The lumen of the object-handling member extends from a first end portion, which is connected to the vacuum module, to a second end portion (herein referred to as the picking end), which is designed for picking, gripping, or otherw ise handling objects. The picking end is ty pically configured to be coupled to a vacuum end effector that attaches to the objects being handled. Due to the negative gauge pressure, the vacuum end effector can pick or grip the objects, as further described below. In various cases, the apparatus is equipped with a gauge sensor for determining the gauge pressure at a test location within the lumen.

[0075] Additionally, the apparatus is equipped with an apparatus controller, as further described below. The apparatus controller is configured to execute a continuous motion of the obj ect-handling member towards an obj ect and implement a soft stop of the continuous motion. The soft stop refers to a method of gradually decelerating and stopping the object-handling member, thereby reducing the impact force of the picking end on the objects being handled. The soft stop can be achieved through specific algorithms implemented in the apparatus controller, as further detailed below.

[0076] FIG. 1 shows, for the purpose of illustration and not limitation, an illustrative vacuum-operated system 100, including a vacuum-operated object-handling apparatus 101. Vacuum-operated object-handling apparatus 101 includes an object-handling member 110 configured to move in at least the vertical direction (Z-axis), as shown in FIG. 1. Additionally, in some cases, the object-handling member 110 can also be configured to move in the X and / or Y directions. This movement capability allows the object-handling member 110 to reach objects located at various positions within its operational range.

[0077] Object-handling member 110 features a connecting member 111 that defines a lumen 112. Connecting member 111 can be of any suitable shape or size to accommodate different operational requirements and spatial constraints. Lumen 112 extends from a first end portion 114 to a second end portion 115. First end portion 114 is designed to fluidly connect to a vacuum module 130 via an actuator system 120. This connection ensures that vacuum module 130 can generate the necessary suction within lumen 112.

[0078] Second end portion 115 of object-handling member 110 is engineered to handle objects, such as consumable 150, as depicted in FIG. 1. In various cases, consumable 150 can be an amplification vessel, a sample lysis vessel, a transfer tip, or any other suitable consumable that can be handled (e.g.. picked up. moved, etc.) by the object-handling member 100. Herein, for generality, such objects are referred to as consumables. This end portion is fluidly connected to the ambient air outside object-handling member 110, allowing vacuum module Patent Application 003168.4560

[0079] 130 to create a suction force when operated. This suction force enables second end portion 1 15 to pick up and securely hold various objects, facilitating their transport and manipulation.

[0080] Vacuum-operated object-handling apparatus 101 further includes a gauge sensor 117 configured to determine the gauge pressure at a test location within lumen 112. Gauge sensor 117 measures the gauge pressure, which is the difference between the pressure inside lumen 112 and the outside atmospheric pressure. A negative gauge pressure within lumen 112 indicates that the pressure inside lumen 112 is lower than the atmospheric pressure. This negative gauge pressure creates a partial vacuum within lumen 112, thereby providing a suction force at second end portion 115.

[0081] In various cases, the vacuum generated within lumen 112 can be significant, and therefore, lumen 112 must be formed from a material capable of withstanding such vacuum. For example, lumen 112 can be constructed from aluminum, steel, or any other suitable material, and can have any appropriate geometrical configuration (e.g., with suitably thick walls) to support a sufficient vacuum, such as about -14 to 0 psi, including all values and ranges in between. Additionally, any suitable leak-proof connections between lumen 112 and actuator system 120 can be used to withstand the required levels of vacuum. In some embodiments, stainless steel tubing, Teflon tubes, vacuum tubing, acetal, and polypropylene materials for the vacuum device can be used.

[0082] It should be noted that actuator system 120 can be optional and object-handling member 110 can be connected directly to vacuum module 130 to establish a fluid communication between vacuum module 130 and lumen 112. In some configurations, the vacuum module 130 can be integrated into the movable components of the device, such as the object-handling member 110. In this setup, the vacuum module 130 can be equipped with pneumatic and powder connections necessary' for its operation.

[0083] Gauge sensor 117 can be any suitable pressure sensor for measuring gauge pressure within lumen 112. As shown in FIG. 1, gauge sensor 117 can be installed at a specific test location on the object-handling member 110 to measure the gauge pressure at that test location. Assuming the flow' is relatively unrestricted between the installation point of gauge sensor 117 (i.e., the test location) and second end portion 115, the pressure drop between the test location and second end portion 115 is expected to be small. Therefore, the gauge pressure at the test location can be used as a good estimate of the gauge pressure within lumen 112 near second end portion 1 15. Patent Application 003168.4560

[0084] In accordance with the disclosed subject matter, gauge sensor 1 17 can be positioned at any suitable location. For example, it can be placed a few inches from the second end portion 115, a few tens of inches from the second end portion 115, or as far as fifty' to one hundred inches from the second end portion 115. Specifically, gauge sensor 117 can be positioned between 0. 1 and 100 inches from the second end portion 115, including all intermediate values and ranges.

[0085] System 100 can detect the start of a sealing action (e.g., the decrease of pressure within lumen 112) within approximately 12 milliseconds, triggering the stop command for the Z-move. An example negative pressure generating system such as a vacuum pump within vacuum module 130 can produce a flow rate of 15 liters per minute, ensuring efficient air movement.

[0086] The vacuum pump of vacuum module 130 can include a vacuum chamber. Alternatively, the vacuum module 130 can operate without a vacuum chamber. Additionally, a vacuum coalescing filter can be used to protect the vacuum pumps and act as a reservoir to create a vacuum spike, aiding in forming a seal. However, the vacuum coalescing filter may not be present, which can reduce the overall evacuated air volume during the pick operation.

[0087] Using small diameter and shorter tubing can offer advantages due to a quicker vacuum response. However, this necessitates placing the pressure gauge close to the vacuum end effector 113. While larger diameter tubing allows for the remote placement of the pressure gauge, it can require an increased cubic feet per minute (CFM) of the vacuum pump to compensate for the larger volume. Without this compensation, the vacuum system's response can be slower.

[0088] Examples of gauge sensors 117 include piezoelectric pressure sensors, which use piezoelectric materials to generate an electric charge in response to applied pressure, providing rapid and precise vacuum measurements. Capacitive pressure sensors can also be used to measure pressure by detecting changes in electrical capacitance caused by diaphragm deformation, offering high sensitivity and fast response times. Additionally, thermocouple vacuum gauges measure vacuum pressure by' detecting temperature changes in a heated filament exposed to varying vacuum levels, ensuring quick response and reliable readings. Vacuum gauges that use a heated wire whose resistance changes with pressure can also measure pressure rapidly and over a wide range. Strain gauge pressure sensors, which use the deformation of a diaphragm under pressure to provide accurate and rapid vacuum measurements, are another option. In various cases, pressure sensors differ in their specific Patent Application 003168.4560 applications, sensitivity, and measurement ranges, making it important to select the appropriate type based on the specific requirements for object handling, such as the size and weight of the objects handled by object-handling member 110.

[0089] While a single gauge sensor 117 is shown in FIG. 1, in some implementations, more than one gauge sensor can be used. Multiple gauge sensors 117 can be employed to ensure redundancy or to obtain an average gauge pressure from several sensors. In some cases, multiple gauge sensors can be used to identify flow within lumen 112. For example, by computing the velocity of gas vi at a first location within lumen 112 using the Bernoulli equation and the known velocity of gas vi at a second location (e.g., at vacuum module 130) as: Vi =2(pi - P2 P +v2 ■

[0090] Vacuum module 130 of vacuum-operated object-handling apparatus 101 can be configured to generate at least a negative gauge pressure within lumen 1 12. Using this negative gauge pressure, objects can be picked up by object-handling member 110. In some cases, vacuum module 130 can also generate a positive or approximately zero gauge pressure within lumen 112. Such positive (or near-zero) gauge pressure can be used to disengage an object from object-handling member 110. Vacuum module 130 can include a pressure-generating system 131, fluidly connected to a valve system 132 via a conduit 133. Pressure-generating system 131 can include a negative pressure generating system 131 A configured to create a negative gauge pressure within lumen 112, and a positive pressure generating system 13 IB configured to create a positive gauge pressure within lumen 112. In some cases, a single pressure generating system can be used to generate both positive and negative gauge pressures within lumen 112.

[0091] Negative pressure generating system 131A can utilize one or more vacuum pumps. Various types of pumps can generate negative gauge pressure. For example, mechanical vacuum pumps, such as rotary vane pumps, use rotating vanes within a cavity to create a vacuum by trapping and compressing gas. Additionally, diaphragm pumps can also be used; these pumps operate by moving a flexible diaphragm to create a variable volume, generating a vacuum without the need for lubricants. Other types of pumps, such as scroll pumps, turbomolecular pumps, diffusion pumps, ejector pumps, or venturi pumps, can also be employed. Depending on the amount of negative gauge pressure required, different pumps can be used, each having specific advantages selected based on application requirements, such as the desired vacuum level, maintenance considerations, and the weight of an object being handled. In some cases, several pumps can be used. For example, a simple diaphragm pump Patent Application 003168.4560 can be used to maintain a lower vacuum level for handling light objects, while a rotary vane pump (or any other suitable vacuum pump) can be used to maintain a higher vacuum level.

[0092] Similarly, positive pressure generating system 131B can utilize various types of pumps to generate positive pressure. Centrifugal pumps, which employ a rotating impeller to add velocity to the fluid and convert it to pressure as the fluid exits the pump, can be used. Reciprocating pumps, rotary screw pumps, gear pumps, peristaltic pumps, diaphragm pumps, axial flow pumps, and others can also be employed to generate positive or near-zero gauge pressure within lumen 112. In some cases, when generating approximately zero gauge pressure within lumen 112, lumen 112 can be simply vented by opening a channel connecting lumen 112 to the surrounding air.

[0093] To achieve additional pressure control within lumen 112, vacuum-operated objecthandling apparatus 101 can utilize chambers beyond the negative pressure generating system 131 A and positive pressure generating system 13 IB. For negative pressure, a dedicated negative pressure chamber can be first evacuated by system 131 A and then connected to lumen 112 through a suitable valve system. Likewise, a pressurized chamber can be employed for positive pressure, achieving pressurization via system 131B before connection to lumen 112 using suitable valves. In accordance with the disclosed subject matter, pressure chambers, and connections can be sufficiently small in order to improve response times in sealing and ejection for system 100. Alternatively, pressure chambers can be omitted.

[0094] In various cases, object-handling member 110 is configured to be movable. The motion of object-handling member 110 is required to move objects from one location to another as they are being picked up. In an example implementation, object-handling member 110 can function similarly to a robotic arm. Object-handling member 110 can be configured to execute a continuous motion at least in the vertical direction (direction Z, as show n in FIG. 1) towards an obj ect. Obj ect-handling member 110 can be designed to descend at a prescribed rate towards the object that needs to be picked, with the descent rate controlled via an apparatus controller 140 (herein, frequently simply referred to as controller 140), as shown in FIG. 1. For example, apparatus controller 140 can adjust the speed of second end portion 115 of object-handling member 110. Specifically, second end portion 115 can be configured to slow down when it is determined that it is in the vicinity of the object that needs to be picked.

[0095] In various cases, the movement of object-handling member 110 can be facilitated by any suitable mechanical devices. For example, actuator system 120 can utilize connecting elements 121A and 121B for moving object-handling member 110. Connecting elements 121A Patent Application 003168.4560 and 121B can be configured to be moved, rotated, or extended such that object-handling member 110 is moved at least along the Z axis. Furthermore, the movement of connecting elements 121A and 121B can further facilitate object-handling member 110 to move along X axis. Connecting elements 121A and 121B can be configured to fluidly connect lumen 112 with vacuum module 130. For example, connecting elements 121A and 121B can include suitable channels (e.g., tubing that is suitable for the vacuum and pressure pneumatics) for connecting vacuum model 130 with lumen 112.

[0096] Elements 121 A and 121B can be joined by coupling element 122. Coupling element 122 allows for rotational or pivoting movement of elements 121 A and 121B, providing objecthandling member 110 with the necessary ability to move. This coupling element 122 ensures that object-handling member 110 can maneuver in one or more directions, including the X and Z axes, facilitating the precise positioning of object-handling member 110. Coupling element 122 enables object-handling member 110 to navigate around obstacles and achieve the correct angle of second end portion 115 for effective object handling. In some cases, coupling element 122 is configured as a rotational joint, allowing elements 121A and 121B to execute rotational motion about a central axis 123 passing through coupling element 122.

[0097] In some cases, connecting element 121 A can be configured to handle broader movements, while element 121B can control finer adjustments. By working together, elements 121A, 122, and 121B enable object-handling member 110 to move smoothly and accurately.

[0098] It should be noted that any other system for controlling the movement of objecthandling member 110 can be used. For example, FIGS. 2A and 2B show actuator systems 220A and 220B of vacuum-operated object-handling apparatus 200A and 200B, respectively. Vacuum-operated object-handling apparatus 200A, shown in FIG. 2A, includes objecthandling member 210A, which can be similar to object-handling member 110 shown in FIG. 1.

[0099] Actuator system 220A includes a vertical rail element 221 A configured to allow a linear guide 223A to slide up and down along the rail, thereby enabling second end portion 215A to move vertically. Additionally, object-handling member 210A can be fluidly connected to a vacuum module 230A using any suitable connection, such as flexible connection 231 A. Connecting elements 224, 226, and 228 are joined via coupling elements 225, 227, and 229, which are configured to allow movement of the connecting elements. These coupling elements can be similar to coupling element 122 shown in FIG. 1 , as they allow for rotational motion of Patent Application 003168.4560 the associated connecting elements 224, 226, and 228 about the central axes of these coupling elements.

[0100] It should be noted that connecting elements 224, 226, and 228, as well as coupling elements 225, 227. and 229, are only illustrative, and any number of coupling and connecting elements can be used. These elements are configured to provide a fluidic channel between vacuum module 230A and object-handling member 210A. While coupling elements 225, 227, and 229 are shown with their axes perpendicular to the X-Z plane, resulting in the movement of connecting elements 224, 226, and 228 within the X-Z plane, in some configurations, the axes of the coupling elements can be parallel to the X-Z plane or have at least some component in the X-Z plane, allowing for movement of object-handling member 210A in and out of the X-Z plane.

[0101] Similar to vacuum-operated object-handling apparatus 101, vacuum-operated object-handling apparatus 200A includes a gauge sensor 217A for measuring gauge pressure within a lumen 212A of object-handling member 210A.

[0102] FIG. 2B shows another illustrative vacuum-operated object-handling apparatus 200B, which includes object-handling member 21 OB. Object-handling member 21 OB can be similar to object-handling member 110 shown in FIG. 1. As shown in FIG. 2B, object-handling member 210B is coupled to a first linear track sliding device 223B configured to slide forward and back along a horizontal tack 221B, enabling a second end portion 215B to move horizontally in the X direction. Additionally, object-handling member 210B is connected to linear track sliding device 223B via a vertical rail element 224B. A connecting element 226B is coupled to vertical rail element 224B via a second track sliding device 225B, which is configured to slide up and down vertical rail element 224B, as indicated by arrow Az. In some cases, object-handling member 210B can be coupled to connecting element 226B via a coupling element 227B, allowing object-handling member 210B to rotate (as indicated by the dashed line representing object-handling member 210B rotating by an angle 0). Such rotation can be advantageous when the surfaces of objects that need to be picked are positioned at an angle to the vertical direction.

[0103] As shown in FIG. 2B, object-handling member 210B is fluidly connected to a vacuum module 230B via a flexible connector 23 IB, thereby eliminating the need for elements 22 IB, 223B-227B to have lumens for fluidly connecting with vacuum module 230B.

[0104] As can be seen from FIGS. 1 , 2A, and 2B, various configurations of actuating systems 120, 220 A, and 220B are possible. It should be noted that actuator systems 120, 220 A, Patent Application 003168.4560 and 220B are only illustrative, and various other systems can be used. In many cases, such actuating systems are configured to move object-handling members at least in the vertical direction (Z) and, in some cases, also in the horizontal directions (X and / or Y). Different elements of actuator systems 120, 220A, and 220B are operated by suitable motors (e.g., electric motors) that can be controlled by apparatus controller 140. In some cases, such motors can be located within coupling elements, such as coupling element 122 shown in FIG. 1, or elements 223A, 225, 227, and / or 229 shown in FIG. 2A, or elements 223B, 225B, and / or 227B shown in FIG. 2B.

[0105] In various cases, object-handling members of vacuum-operated object-handling apparatuses are configured to pick up objects, move them, and release them. For example, as shown in FIG. 1, object-handling member 110 is designed to pick up consumable 150 at a first location and move it to a second location by executing motions in the vertical direction (Z), lateral direction (X). lateral direction (Y), or any combination thereof. Additionally, objecthandling member 110 is configured to release consumable 150 at the second location. In various examples, consumable 150 can be picked up by generating a negative gauge pressure within lumen 112 of object-handling member 110, and it can be released by venting lumen 112, thereby setting the gauge pressure to about zero or a positive value. Additionally, or alternatively, a positive gauge pressure can be generated within lumen 112 to further facilitate the release of consumable 150.

[0106] Returning to FIG. 1, object-handling member 110 can include a vacuum end effector 113 configured to attach to objects being handled. Vacuum end effector 113 can be configured to couple to object-handling member 110 at second end portion 115. For example, connecting member 111 of object-handling member 110 can be coupled to vacuum end effector 113 at second end portion 115.

[0107] In some cases, vacuum end effector 113 can be coupled to connecting member 111 at second end portion 115 via any suitable coupling, such as sleeve coupling, flange coupling, threaded coupling, push-to-connect coupling, snap-on coupling, quick-release coupling, clamped coupling, as well as electro-magnetic coupling, or any other coupling. Vacuum end effector 113 can be selected from a set of vacuum end effectors, each one of the set of vacuum end effectors configured to handle a particular object from a set of objects. In some cases, controller 140 can be configured to automatically decouple a vacuum end effector via the end effector coupling and automatically couple vacuum end effector 1 13 via the end effector Patent Application 003168.4560 coupling. Such coupling is configured to be airtight to ensure that vacuum end effector 113 can seal against a surface of an object being picked.

[0108] In some cases, vacuum end effector 113 is formed from a flexible material, such as silicone elastomer, rubber, plastic, closed cell foam, or a combination thereof.

[0109] It should be noted that forming the vacuum end effector 113 from the flexible material is only illustrative and other non-flexible materials can be used. For example, with sufficient suction, an obj ected can be picked even with leakage between the effector and the object that is being picked. For example, vacuum end effector 113 can include a highly polished hard surface for manipulating at least some objects, particularly, a polished aluminum surface can be used for vacuum end effector 113 to self-align and manipulate some objects.

[0110] It should be noted that the materials listed above are only illustrative, and any other flexible materials can be used. For example, a silicone can be used having a durometer hardness of 70A. The durometer scale measures the hardness of materials, with higher numbers indicating harder materials. A durometer of 70A for silicone rubber means it has a medium firmness — neither too soft nor too hard. In various embodiments, if the silicone rubber is too hard, around 90A or more of durometer hardness, the end effectors can become excessively stiff, making it difficult to create a reliable seal around the object they are meant to grip. This lack of flexibility can result in a poor seal, leading to air leaks that interfere with the functioning of devices that rely on suction or vacuum mechanisms. Conversely, if the silicone rubber is too soft, around 50A or less, the end effectors can become overly flexible, causing the tips to deform excessively. This deformation can result in the end effector jamming into the item it is trying to pick up. making the item get stuck on the end effector and hindering smooth operation.

[0111] Vacuum end effector 113 includes an outward surface 1 18, as shown in FIG. 1, which can be configured to be flat and contain a hole. This hole allows for a passage between lumen 112 and the surrounding air near the object-handling member 110. Generally, the vacuum end effector 113 (also referred to as a consumable loader) features a flat bottom to ensure proper orientation of the picked objects, which ty pically have a flat or pickable surface. In various embodiments, the vacuum end effector 113 may have a single hole to provide a passage between lumen 112 and the ambient air. The vacuum end effector 113 is designed to perform two functions: sealing the object to the open lumen 112 using negative pressure and maintaining the object's orientation. Typically, the bottom of the vacuum end effector 113 is flat to keep the picked object perpendicular to the tray or surface from which it is being picked, ensuring precision in picking and placing. Patent Application 003168.4560

[0112] FIGS. 3 A and 3B show respective vacuum end effectors 313 A and 313B with tubular hollow element 318A and 318B, having corresponding holes 319A and 319B. Tubular elements 318A and 318B include lumens 317A and 317B for facilitating air intake and forming a vacuum used for picking up consumables. In various cases, elements 318A can be inserted into a suitable consumable. Vacuum end effectors 313A and 313B, as shown, include corresponding lip elements 316A and 316B, which can be configured to seal a tubular consumable object.

[0113] FIG. 3C shows a vacuum end effector 313C having an element 320C designed to be adjacent to an open side of a consumable, thereby sealing (or at least partially sealing) that open side of the consumable and causing a partial vacuum within that consumable. FIG. 3C shows element 320C positioned at a first location, in a mid-section of an element 318C, while FIG. 3D shows another vacuum end effector 313D having a hollow element 318D and element 320D positioned at a second location, closer to the end of an element 320D.

[0114] In various cases, different types of vacuum end effectors can be used for picking up different types of objects. For example, vacuum end effector 313A can be used for picking up tubular consumables, while vacuum end effector 313E, as shown in FIG. 3E, is configured to pick up flat objects such as tray 340E. These vacuum end effectors can be designed to be easily replaceable. In some cases, the replacement can be done manually, and in other cases, the replacement can be done automatically.

[0115] FIGS. 3F-3H illustrate a vacuum end effector 313G. FIG. 3F shows vacuum end effector 313G with an element El, designed to be adjacent to the top portion of a sample lysis vessel 01, as depicted in FIG. 3G, to seal the sample lysis vessel 01. Additionally, vacuum end effector 313G includes another element E2, configured to be adjacent to a smaller object, such as a transfer tip 02, as shown in FIG. 3H, to seal the transfer tip 02. This embodiment includes an extended tubular element E3 containing a lumen. Tubular element E3 is designed to create a vacuum within objects such as the sample lysis vessel 01 or the transfer tip 02 by suctioning air through the lumen of element E3.

[0116] FIGS. 3I-3K illustrate another exemplar}' vacuum end effector 313H, in accordance with the disclosed subject matter. FIG. 31 shows vacuum end effector 313H with an element E4, designed to be adjacent to the top portion of an amplification vessel 03, as depicted in FIG. 3J, to seal the vessel 03. Additionally, as shown in FIG. 3K. element E4 may also be used to pick up a cap 04, as it can be configured to seal the cap 04. Vacuum end effector 313H includes an extended tubular element E5 containing a lumen. Element E5 can be similar to or the same Patent Application 003168.4560 as element E3 of vacuum end effector 313G. Tubular element E5 is designed to create a vacuum to create a seal to pick objects. Element E4, as shown in FIGS. 3I-3K is configured to be positioned close to the tip of extended tubular element E5, whereas elements El and E2, as shown in FIGS. 3F-3H, which are functionally similar to element E5. are positioned further away from the tip of extended tubular element E3 (which is similar to element E5).

[0117] FIG. 3L show-s an example w ash vessel 05, which is the same as object 340E shown in FIG. 3E. FIGS. 3M-3O show an example vacuum end effector 3131, which can be similar to or the same as vacuum end effector 313H. Similar to vacuum end effector 313H. vacuum end effector 3131 includes element E6, as shown in FIG. 30, which can be similar to element E4 of vacuum end effector 313H, and element E7, which can be similar to or the same as extended tubular element E5 of vacuum end effector 313H and / or element E3 of vacuum end effector 313G.

[0118] When releasing an object, if the object has sufficient mass and / or a low contact area, positive pressure may not be required to release it from vacuum end effector 113. However, positive pressure can be necessary when the objects being picked are of low mass and / or have a large contact area with vacuum end effector 113. Additionally, when the release time is short (e.g., a few milliseconds), positive pressure can be used to facilitate the release of the object.

[0119] A vacuum-operated system can include a storage area for different vacuum end effectors. Object-handling member 110 can move to this storage area, release the currently used vacuum end effector using a suitable release mechanism, and couple the object-handling member 110 with a different vacuum end effector from the storage. This allows the system to handle various types of objects efficiently.

[0120] For instance, an electromagnetic coupling can be used to attach and detach vacuum end effectors to / from the object-handling member. The electromagnetic coupling operates by using an electromagnet to magnetically couple to a magnetic or metallic region (e.g., a rim) of a vacuum end effector. The vacuum end effector is released by turning off the electromagnet. This system allows for quick and efficient changes betw een different vacuum end effectors.

[0121] Returning to FIG. 1 , the vacuum-operated system can include a tray 160, and obj ecthandling member 110 can be configured to pick up objects from tray 160. Tray 160 can contain different types of consumable, such as sample lysis vessels 151. tip objects 153, or other consumables 152. In some cases, tray 160 can be configured to move in a straight line along a particular direction (e.g., the Y direction), thereby reducing the degrees of freedom required for object-handling member 110 to access different objects. Patent Application 003168.4560

[0122] For instance, if object-handling member 110 moves in the X and Z directions while tray 160 moves in the Y direction, object-handling member 110 can reach any object within the X, Y, Z space. In some cases, if tray 160 is configured to move in both the X and Y directions, it is sufficient for object-handling member 110 to only move in the Z direction to reach any object residing at various X, Y, Z coordinates. In general, however, object-handling member 110 can be configured to move in two or even three directions.

[0123] In various cases, control of movement of object-handling member 110 as well as control of vacuum module 130 is performed by apparatus controller 140. One illustrative diagram of apparatus controller 140 is shown in FIG. 4.

[0124] Controller 140 can be configured to perform one or more parts of the methods described or illustrated herein. Controller 140 also provides the functionality described or illustrated in various cases. Additionally, software running on controller 140 can perform one or more parts of the methods or provide the functionality described herein. References to controller 140 can encompass a computing device, and vice versa, where appropriate. Moreover, references to a controller can encompass one or more controllers, where appropriate.

[0125] This disclosure contemplates that more than one controller 140 can be used. Controller 140 can take any suitable physical form. For example, and not by way of limitation, controller 140 can be an embedded computer system, a system-on-chip (SoC), a single-board computer system (SBC) (such as, for example, a computer-on-module (COM) or system-on- module (SOM)), a desktop computer system, a laptop or notebook computer system, a mainframe, a mesh of computer systems, a mobile telephone, a personal digital assistant (PDA), a server, a tablet computer system, an augmented / virtual reality device, or a combination of two or more of these. Where appropriate, controller 140 can include one or more subcontrollers; be unitary’ or distributed; span multiple locations; span multiple machines; span multiple data centers; or reside in a cloud, which can include one or more cloud components in one or more networks. As an example, and not by way of limitation, controller 140 can perform one or more procedures in real-time or in batch mode, or at selected times, as described or illustrated herein.

[0126] In accordance with the disclosed subject matter, controller 140 can include a processor 141, memory 142, storage 143, an input / output (I / O) interface 144, a communication interface 145, and a bus 146. Although this disclosure describes and illustrates a particular controller with a specific number of components arranged in a particular manner, it Patent Application 003168.4560 contemplates any suitable controller with any suitable number of components in any suitable arrangement.

[0127] In a particular implementation, processor 141 includes hardware for executing instructions, such as those making up a computer program. As an example, and not by way of limitation, to execute instructions, processor 141 can retrieve (or fetch) the instructions from an internal register, an internal cache, memory 142, or storage 143; decode and execute them; and then write one or more results to an internal register, an internal cache, memory7142, or storage 143. In a particular implementation, processor 141 can include one or more internal caches for data, instructions, or addresses. This disclosure contemplates processor 141 including any suitable number of any suitable internal caches, where appropriate. As an example, and not by way of limitation, processor 141 can include one or more instruction caches, one or more data caches, and one or more translation lookaside buffers (TLBs). Instructions in the instruction caches can be copies of instructions in memory 142 or storage 143, and the instruction caches can speed up retrieval of those instructions by processor 141. Data in the data caches can be copies of data in memory7142 or storage 143 for instructions executing at processor 141 to operate on; the results of previous instructions executed at processor 141 for access by subsequent instructions executing at processor 141 or for writing to memory 142 or storage 143; or other suitable data. The data caches can speed up read or write operations by processor 141. The TLBs can speed up virtual-address translation for processor 141. In some cases, processor 141 can include one or more internal registers for data, instructions, or addresses. This disclosure contemplates processor 141 including any suitable number of any suitable internal registers, where appropriate. Where appropriate, processor 141 can include one or more arithmetic logic units (ALUs); be a multi-core processor; or include one or more processors. Although this disclosure describes and illustrates a particular processor, this disclosure contemplates any suitable processor.

[0128] In some cases, memory 142 includes main memory for storing instructions for processor 141 to execute or data for processor 141 to operate on. As an example, and not by way of limitation, controller 140 can load instructions from storage 143 or another source (such as, for example, another controller 140) to memory7142. Processor 141 can then load the instructions from memory 142 to an internal register or internal cache. To execute the instructions, processor 141 can retrieve the instructions from the internal register or internal cache and decode them. During or after the execution of the instructions, processor 141 can write one or more results (which can be intermediate or final results) to the internal register or Patent Application 003168.4560 internal cache. Processor 141 can then write one or more of those results to memory 142. In some cases, processor 141 executes only instructions in one or more internal registers or internal caches or in memory' 142 (as opposed to storage 143 or elsewhere) and operates only on data in one or more internal registers or internal caches or in memory 142 (as opposed to storage 143 or elsewhere). One or more memory buses (which can each include an address bus and a data bus) can couple processor 141 to memory 142. Bus 146 can include one or more memory buses, as described below. One or more memory management units (MMUs) reside between processor 141 and memory 142 and facilitate accesses to memory’ 142 requested by processor 141. Memory 142 includes random access memory (RAM). This RAM can be volatile memory, where appropriate. Where appropriate, this RAM can be dynamic RAM (DRAM) or static RAM (SRAM). Moreover, where appropriate, this RAM can be singleported or multi-ported RAM. This disclosure contemplates any suitable RAM. Memory' 142 can include one or more memories, where appropriate. Although this disclosure describes and illustrates a particular memory, this disclosure contemplates any suitable memory.

[0129] Storage 143 includes mass storage for data or instructions. As an example, and not by way of limitation, storage 143 can include a hard disk drive (HDD), a floppy disk drive, flash memory’, an optical disc, a magneto-optical disc, magnetic tape, or a Universal Serial Bus (USB) drive or a combination of two or more of these. Storage 143 can include removable or non-removable (or fixed) media, where appropriate. Storage 143 can be internal or external to controller 140, where appropriate. Storage 143 can be a non-volatile, solid-state memory'. Storage 143 can include read-only memory (ROM). Where appropriate, this ROM can be mask-programmed ROM, programmable ROM (PROM), erasable PROM (EPROM), electrically erasable PROM (EEPROM), electrically' alterable ROM (EAROM), flash memory, or a combination of two or more of these. This disclosure contemplates mass storage 143 taking any suitable physical form. Storage 143 can include one or more storage control units facilitating communication between processor 141 and storage 143. where appropriate. Where appropriate, storage 143 can include one or more storages. Although this disclosure describes and illustrates particular storage, this disclosure contemplates any suitable storage.

[0130] In some cases, I / O interface 144 includes hardware, software, or both, providing one or more interfaces for communication between controller 140 and one or more I / O devices. Controller 140 can include one or more of these I / O devices, where appropriate. One or more of these I / O devices can enable communication between a person and controller 140. As an example, and not by way of limitation, an I / O device can include a keyboard, keypad, Patent Application 003168.4560 microphone, monitor, mouse, printer, scanner, speaker, still camera, stylus, tablet, touch screen, trackball, video camera, another suitable I / O device or a combination of two or more of these. An I / O device can include one or more sensors. This disclosure contemplates any suitable I / O devices and any suitable I / O interfaces 144 for them. Where appropriate, I / O interface 144 can include one or more device or software drivers enabling processor 141 to drive one or more of these I / O devices. I / O interface 144 can include one or more I / O interfaces 144, where appropriate. Although this disclosure describes and illustrates a particular I / O interface, this disclosure contemplates any suitable I / O interface.

[0131] Communication interface 145 includes hardware, software, or both providing one or more interfaces for communication (such as, for example, packet-based communication) between controller 140 and one or more other controllers 140 or one or more networks. As an example, and not by way of limitation, communication interface 145 can include a network interface controller (NIC) or network adapter for communicating with an Ethernet or other wire-based network or a wireless NIC (WNIC) or wireless adapter for communicating with a wireless network, such as a WI-FI network. This disclosure contemplates any suitable network and any suitable communication interface 145 for it. As an example, and not by way of limitation, controller 140 can communicate with an ad hoc network, a personal area network (PAN), a local area network (LAN), a wide area network (WAN), a metropolitan area network (MAN), or one or more portions of the Internet or a combination of two or more of these. One or more portions of one or more of these networks can be wired or wireless. As an example, controller 140 can communicate with a wireless PAN (WPAN) (such as, for example, a BLUETOOTH WPAN). a WI-FI network, a WI-MAX network, a cellular telephone network (such as, for example, a Global System for Mobile Communications (GSM) network, a Long- Term Evolution (LTE) network, or a 5G network), or other suitable wireless network or a combination of two or more of these. Controller 140 can include any suitable communication interface 145 for any of these networks, where appropriate. Communication interface 145 can include one or more communication interfaces 145, where appropriate. Although this disclosure describes and illustrates a particular communication interface, this disclosure contemplates any suitable communication interface.

[0132] Bus 146 includes hardware, software, or both coupling components of controller 140 to each other. As an example, and not by way of limitation, bus 146 can include an Accelerated Graphics Port (AGP) or other graphics bus, an Enhanced Industry Standard Architecture (EISA) bus, a front-side bus (FSB), a HYPERTRANSPORT (HT) interconnect, Patent Application 003168.4560 an Industry Standard Architecture (ISA) bus, an INFINIBAND interconnect, a low-pin-count (LPC) bus, a memory bus, a Micro Channel Architecture (MCA) bus, a Peripheral Component Interconnect (PCI) bus, a PCI-Express (PCIe) bus, a serial advanced technology attachment (SATA) bus, a Video Electronics Standards Association local (VLB) bus, or another suitable bus or a combination of two or more of these. Bus 146 can include one or more buses 146, where appropriate. Although this disclosure describes and illustrates a particular bus, this disclosure contemplates any suitable bus or interconnect.

[0133] Herein, a computer-readable non-transitory storage medium or media can include one or more semiconductor-based or other integrated circuits (ICs) (such, as for example, field- programmable gate arrays (FPGAs) or application-specific ICs (ASICs)), hard disk drives (HDDs), hybrid hard drives (HHDs), optical discs, optical disc drives (ODDs), magneto-optical discs, magneto-optical drives, floppy diskettes, floppy disk drives (FDDs), magnetic tapes, solid-state drives (SSDs), RAM-drives, SECURE DIGITAL cards or drives, any other suitable computer-readable non-transitory storage media, or any suitable combination of two or more of these, where appropriate. A computer-readable non-transitory storage medium can be volatile, non-volatile, or a combination of volatile and non-volatile, where appropriate.

[0134] In various cases, an apparatus controller, such as apparatus controller 140, is configured to control the motion of an object-handling member, such as object-handling member 110. Controller 140 is designed to send signals to various motors operating different actuators to move object-handling member 110 to a prescribed position. For example, controller 140 can control object-handling member 110 to execute continuous motion in the vertical Z direction, continuous motion in one of the horizontal X and / or Y directions, continuous motion in the vertical Z and horizontal X directions, continuous motion in the vertical Z and horizontal Y directions, and / or any other continuous motion. In some cases, a discontinuous motion can also be performed by object-handling member 110 and can be controlled by controller 140.

[0135] The motors controlled by controller 140 can include servo motors, stepper motors, DC motors (including brushless DC motors), as well as various linear actuators, and pneumatic and hydraulic actuators. These motors are configured to move the connecting elements of actuator system 120 or any other suitable actuators, as shown in FIGS. 2A and 2B.

[0136] In operation, a signal from a gauge sensor, such as gauge sensor 117, as shown in FIG. 1, can be used to determine various aspects of how object-handling member 110 should be moved. Patent Application 003168.4560

[0137] For example, when the gauge pressure within lumen 1 12, as shown in FIG. 1 , falls below a prescribed gauge pressure threshold value, a signal from controller 140 can be sent to the motors of vacuum-operated object-handling apparatus 101 to execute a soft stop of the continuous motion of object-handling member 110. The prescribed gauge pressure threshold value can be any suitable selected pressure threshold. For example, the prescribed gauge pressure threshold can be -0.1 of atmospheric pressure or -10% of the percentage gauge pressure (PGP). Gauge pressure thresholds can range from -0.05% to -99% PGP, including all intermediate values (with -100% PGP representing an absolute vacuum).

[0138] The soft stop includes performing a deceleration of object-handling member 110 by utilizing a prescribed deceleration profile characterizing a reduction of the velocity of motion of the object-handling member as a function of time. For example, the deceleration profile can be a function relating the velocity of movement of object-handling member 110 and time. For instance, an example deceleration profile can be an exponential deceleration profile given by v(t)=roeAt. where v(t) is the velocity at time t, vo is the initial velocity at t=0, is the decay constant (a positive value), and e is Euler number (approximately equal to 2.71828). The position profile can then be given by r(t)=kvo ( 1 e / t) - ro. with ro being an initial position prior to executing the soft stop. It should be noted that exponential deceleration is only one illustrative example, and any other suitable profile, such as quadratic profile, is possible (quadratic profile is given by v(t)=vo~«t2, with r(t)=vot - « / 3 t3+ro, and a is a constant that determines the rate of deceleration). Note, that in various implementations, v, r, and a, can be vectors).

[0139] Additionally, or alternatively, when a change in gauge pressure within lumen 112 exceeds a gauge pressure change threshold value, a signal from controller 140 can be sent to the motors of vacuum-operated object-handling apparatus 101 to execute a soft stop of the continuous motion of object-handling member 110. The prescribed gauge pressure change threshold value can be any suitably selected value. For example, if the gauge pressure changes w ithin a time window of one-tenth of a second by an amount of one-tenth of an atmosphere, the gauge pressure change rate can be 1 atmosphere / second (atm / s). In various cases, the gauge pressure change threshold can range between 0. 1-10 atm / s, including all intermediate values.

[0140] FIGS. 5 A and 5B show example profile plots of gauge pressure profile 510 within lumen 112 (FIG. 5A) and changes in gauge pressure profile 520 (FIG. 5B), and FIG. 5C shows an example profile plot of power profile 530 supplied to a vacuum module 130. It should be noted that the example profile plots (herein also referred to as profiles) are only illustrative, Patent Application 003168.4560 and other suitable profiles can be used. Furthermore, at least some profiles can be used for implementing operations of vacuum-operated object-handling apparatus 101, while other profiles cannot be used (e.g., power profile 530 cannot be used).

[0141] As seen in FIG. 5A, gauge pressure profile 510 starts at an initial "open" pressure, which can be, for example, approximately zero when object-handling member 110 is far from the object requiring handling (e.g., far from consumable 150). As another example, the open pressure can be negative when vacuum end effector 113 has not contacted an object to be picked. The open pressure value can be determined by the orifice size of lumen 112, the length and diameter of the tubing from negative pressure generating system 131A (e.g., a vacuum pump) of vacuum module 130, and the capacity of the vacuum pump.

[0142] As shown, gauge pressure profile 510 decreases as object-handling member 110 approaches closely to consumable 150, e.g., as shown by time Tp. During this approach, consumable 150 obstructs the flow generated by vacuum module 130, leading to an overall reduction in gauge pressure profile 510 within lumen 112.

[0143] When object-handling member 110 is in proximity to consumable 150 (e.g., when vacuum end effector 113 is adjacent to the surface of consumable 150), gauge pressure profile 510 drops significantly at contact time Tc, falling below the gauge pressure threshold value GT, as shown in FIG. 5A. Beyond time Tc, the gauge pressure can stabilize at a constant value, which cannot reach the negative one atmosphere value due to the presence of leaks allowing air to enter lumen 112. These leaks can occur in the connecting elements, which can use gaskets, O-rings, seals, and similar components, or between the imperfect coupling of consumable 150 and vacuum end effector 113. The time Tc can be used as a time to initiate a soft stop for object-handling member 110, and at this time controller 140 can be configured to send a signal to various motors of vacuum-operated object-handling apparatus 101 to initiate the soft stop.

[0144] In various cases, an apparatus controller, such as controller 140, as shown in FIG. 1 is configured to determine a change in the gauge pressure as object-handling member 110 executes a continuous motion towards consumable 150. FIG. 5B shows change gauge pressure profile 520 which shows a noticeable change in the gauge pressure at time Tc. This change can be evaluated as a derivative of gauge pressure profile 510 over time, and it is largest at time Tc. When the change in gauge pressure profile 520 is less than a given gauge pressure change threshold value CGT at time To, which can be slightly before or at time Tc, a soft stop procedure can be initiated by controller 140. Alternatively, in some implementations, a slow-down Patent Application 003168.4560 procedure can be initiated by controller 140 at time To, with the soft stop procedure initiated at time Tc. The slow-down procedure can be similar to the soft stop procedure, with the primary difference being the deceleration profile used. For example, the deceleration profile during the slow-down procedure does not require object-handling member 110 to come to a complete stop, while the soft stop procedure does require a complete halt of object-handling member 110.

[0145] It should be appreciated that, in some implementations, changes in the movement of object-handling member 110 can be accompanied by changes in the operation of the pressure-generating system 131 of vacuum module 130. For example, when object-handling member 110 is moving far away from consumable 150, pressure-generating system 131 can be disengaged or not fully engaged, as indicated by low values of power profile 530 delivered to power generating system 131 of vacuum module 130, as shown in FIG. 5C. However, as objecthandling member 110 approaches consumable 150, pressure-generating system 131 can become engaged or increase the suction generated. This is indicated by an increase in power profile 530 as object-handling member 110 approaches consumable 150. Such an increase ensures that power is only used in proximity to consumable 150, and not wasted when objecthandling member 110 passes next to other objects that could inadvertently be picked up or agitated if power profile 530 were not reduced.

[0146] As an example, when the change in gauge pressure exceeds a prescribed power- associated threshold CGo at time Tp, the power profile 530 for pressure-generating system 131 can increase significantly. For instance, the power can increase twofold to tenfold, including all intermediate values. In one example implementation, pressure generating system 131 can operate in a full power mode at power WF and in a standby power mode at power Wo. When proximate to an object, as indicated by the change in gauge pressure profile 520 being below a specified power-related threshold CGo, pressure generating system 131 can be configured to start operating at full power. When away from consumable 150, pressure generating system 131 can operate at standby power Wo, which can be a fraction of full power (e.g., WO / WF might be about 0.1, 0.2, 0.3, etc.).

[0147] Alternatively, power can only be either turned off or turned on. In the "ON" power configuration, the power delivered to the pressure generating system 131 can be constant. This configuration can be selected for its cost-effectiveness and responsiveness.

[0148] In various cases, gauge pressure measurements by gauge sensor 1 17, as shown in FIG. 1, are performed at a relatively high frequency to obtain a continuous reading of gauge Patent Application 003168.4560 pressure within lumen 1 12. In one example implementation, the gauge pressure is monitored at a set frequency. For example, the set frequency can be about one thousand measurements per second, resulting in a gauge pressure sensor obtaining gauge pressure data every millisecond. In some cases, gauge pressure can be measured every few milliseconds, and in other implementations, it can be measured every fraction of a millisecond, such as every half millisecond or ever}7one-third millisecond. The frequency of measuring gauge pressure can depend on the speed at which object-handling member 110 is moving. For instance, when object-handling member 110 is moving slowly, the measurement frequency f can be reduced and related to the speed v of object-handling member 110 by the expression / =Cv, where C is a constant and measured in units of [I / meter], Alternatively, the frequency / can be constant. In some cases, the frequency / can increase as object-handling member 110 moves closer to consumable 150, which can be determined by analyzing changes in gauge pressure using any suitable approach as described above. For example, the frequency f can increase when the change in gauge pressure profile 520 is lower than a prescribed threshold CGo.

[0149] In various cases, controller 140 can be configured to compute a running average of the gauge pressure over a first predetermined time window and compute the change in gauge pressure by calculating the difference in the running average over a second predetermined time window. In an example implementation, the first predetermined time window can be a few milliseconds or a Pew tens of milliseconds, such as 10, 20, 30, 40, 50, 60, 70, 80, or 90 milliseconds, or any value between 5 and 100 milliseconds, while the second predetermined time window can be a few tens of milliseconds or a few hundreds of milliseconds. The first and second predetermined time windows can be selected depending on the speed of objecthandling member 110. For example, when object-handling member 1 10 is configured to move rapidly, the first and second time windows can be reduced, and when object-handling member 110 is configured to move slowly, these time windows can be increased. In some cases, the characteristic duration of these time windows is inversely proportional to the speed of objecthandling member 110 as selected by controller 140.

[0150] In accordance with the disclosed subject matter, the first predetermined time window7can be approximately 10 milliseconds, with the gauge pressure sampled every few7milliseconds. For instance, the gauge pressure can be sampled every 1 millisecond, 1.25 milliseconds. 1.5 milliseconds. 2 milliseconds, or similar intervals. In some cases, the sampling interval can be 5%, 10%, 15%, or 20% of the predetermined time window, among other possible percentages. Patent Application 003168.4560

[0151] As previously described, pressure generating system 131 of vacuum module 130 can be configured to generate a negative gauge pressure within lumen 112, as shown in FIG. 1 , or a positive gauge pressure. In one example implementation pressure generating system 131 can include a suitable pump that is configured to generate both positive and negative gauge pressures. However, in some other cases, separate negative pressure generating system 131 A and positive pressure generating system 13 IB can be used. Such systems can be coupled to lumen 112 via valve sy stem 132.

[0152] An example configuration of a vacuum module 630 is shown in FIG. 6A. Vacuum module 630 can be similar or identical in structure and function to vacuum module 130, as shown in FIG. 1. Vacuum module 630 includes a pressure generating system 631, which comprises a negative pressure generating system 631 A (similar to negative pressure generating system 131 A), a positive pressure generating system 63 IB (similar to positive pressure generating system 13 IB), and optionally, a negative pressure chamber 631C and a positive pressure chamber 631D. These pressure generating systems and chambers 631A-631D are fluidly connected to a connecting element 621 A (similar to connecting element 121A, as show n in FIG. 1) via channels 633A-633D.

[0153] In various cases, channels 633A-633D are controlled by valves 634A-634D, which can open or close the fluid communication via channels 633A-633D. It should be noted that while four valves 634A-634D are show n, a single valve or multiple valves can be used to switch fluid communication for different channels. Generally, any number of valves can be used to determine the proper fluidic connections between the pressure generating systems and chambers 631A-631D and the connecting element 621 A.

[0154] In one case, valve system 632 can have at least a first and a second configuration. In the first configuration, valve system 632 is arranged to fluidly connect a lumen of a vacuum- operated object-handling apparatus, via, for example, connecting element 621 A, with the negative pressure-generating system 631 A. In the second configuration, it is arranged to fluidly connect the lumen with the positive pressure-generating system 63 IB. Thus, when valve system 632 is in the first configuration, a negative gauge pressure is created in the lumen by operating the negative pressure-generating system 631 A, and when valve system 632 is in the second configuration, a positive gauge pressure is created in the lumen by operating the positive pressure-generating system 63 IB.

[0155] In some cases, when negative pressure chamber 631 C is present, it can be maintained at a negative gauge pressure by fluidly connecting negative pressure-generating Patent Application 003168.4560 system 631 A to negative pressure chamber 631 C via a channel 635 A with an associated valve 636A, which can be controlled to open and close channel 635A. When negative pressure chamber 631C is under negative gauge pressure, it can be configured to connect via channel 633C with the lumen by means of connecting element 621 A. In various cases, controller 640 (similar or identical to controller 140, as shown in FIG. 1) can determine which valves to open based on the gauge pressure within negative pressure chamber 631C. For example, if negative pressure chamber 631C is at the required negative pressure, valve 634C can be opened. If it is not at the required negative pressure, valve 634C can be closed while valve 636A is opened to reduce the gauge pressure within the negative pressure chamber 631C.

[0156] Similarly, when positive pressure chamber 631D is present, it can be maintained at a positive gauge pressure by fluidly connecting positive pressure-generating system 63 IB to positive pressure chamber 631D via a channel 635B with an associated valve 636B, which can be controlled to open and close channel 635B. When positive pressure chamber 63 ID is under positive gauge pressure, it can be configured to connect via channel 633D with the lumen by means of connecting element 621 A. In various cases, controller 640 can determine which valves to open based on the gauge pressure within positive pressure chamber 63 ID. For example, if positive pressure chamber 63 ID is at the required positive pressure, valve 634D can be opened. If it is not at the required positive pressure, valve 634D can be closed while valve 636B is opened to increase the gauge pressure within positive pressure chamber 63 ID.

[0157] In various cases, controller 640 can be configured to fluidly couple the negative pressure chamber 631C to the lumen when the negative pressure-generating system 631 A is disabled or has failed. In such a situation, the valve system 632 can be in a third configuration, fluidly coupling the lumen to the negative pressure chamber 631C.

[0158] Furthermore, controller 640 can be configured to place valve system 632 into a fourth configuration, in which the lumen is fluidly coupled to the positive pressure chamber 63 ID.

[0159] As shown in FIG. 6A, controller 640 can control any of the valves in valve system 632 as well as valves 636A and 636B of the pressure generating system 631. Additionally, controller 640 is configured to control power to the pressure generating systems 631 A and 63 IB. As shown in FIG. 6A, controller 640 can be electrically connected to vacuum module 630 via an electrical connection 644. Electrical connection 644 is configured to provide data and power to different components of vacuum module 630. Patent Application 003168.4560

[0160] FIG. 6B illustrates an example diagram 631 including a series of vacuum pumps, transducers, valves, and vacuum end effectors arranged for use with a vacuum-operated system, such as system 100. The vacuum-operated system features three vacuum pumps, 652A, 652B, and 652C, located in the pump bay lower deck. These pumps are connected to corresponding vacuum transducers 653A, 653B, and 653C through tubing. Positioned in the stationary components section of the vacuum-operated system, the transducers monitor and regulate the vacuum pressure delivered to various vacuum end effectors (VEEs), as shown in FIG. 6B.

[0161] The moving portion of the vacuum-operated system houses a series of valves 654A to 654E that control the flow of vacuum to vanous vacuum end effectors. Each vacuum transducer 653A-653C is connected to a valve and measures the vacuum in the lumen.

[0162] Additionally, the system includes a pressure pump 657, which provides the necessary' pressure for the system. The pressure pump is connected to a series of filters and a pressure regulator to ensure a clean and regulated air supply. The filters include a filter 658 that protects the pressure pump, a filter 659 that forms part of the airflow filtration system, and a HEPA filter 656 that further purifies the air before it enters the pressure regulator. The pressure regulator maintains the desired pressure within the system, while a pressure transducer 655, located in the stationary components section of the vacuum-operated system, monitors and regulates the pressure delivered to the vacuum end effectors.

[0163] In operation, the vacuum pumps generate vacuum pressure, which the transducers monitor to ensure the correct vacuum level is achieved. The valves distribute the vacuum to the appropriate vacuum end effectors based on the task required. The pressure pump supplies the necessary pressure, which is filtered and regulated to meet the system's requirements.

[0164] Methods of Controlling the Vacuum-Operated System

[0165] FIG. 7 show s an illustrative method 700 performed by an apparatus controller, such as controller 140 shown in FIG. 1. Method 700 includes, at 710, monitoring changes in gauge pressure measurements within a lumen, such as lumen 112, at a set frequency using a gauge pressure sensor. At s712, method 700 includes executing a continuous motion of an objecthandling member, such as object-handling member 110 shown in FIG. 1. This continuous motion can be performed at least in the vertical direction towards an object that needs to be handled, such as consumable 150 shown in FIG. 1. Furthermore, at 714, method 700 includes executing a soft stop of the continuous motion when the change in gauge pressure, as determined by the gauge sensor, is below a threshold. Patent Application 003168.4560

[0166] FIG. 8 shows an illustrative method 800 performed by a suitable system controller associated with a vacuum-operated system, such as vacuum-operated system 100. The system controller can be configured to perform control actions for other elements of vacuum-operated system 100 that are not related to the object-handling apparatus 101. For example, the system controller can be configured to move a tray, such as tray 160 shown in FIG. 1, or actuate any other suitable devices in the vicinity of the vacuum-operated object-handling apparatus 101. In various cases, the system controller can perform control actions in coordination with apparatus controller 140. For example, the system controller can transmit data to and from apparatus controller 140, wherein the data includes, for example, instructions to apparatus controller 140, or feedback data from apparatus controller 140.

[0167] Method 800 includes, at 810, determining the lateral coordinate position where an object (e.g., consumable 150, as shown in FIG. 1) should be placed to be handled by the vacuum-operated object-handling apparatus 101. This position corresponds to coordinates {Xo, Yo} in the horizontal plane. At 812, method 800 includes moving the tray in the first lateral direction (e.g., in the Y direction, as shown in FIG. 1) by a first distance selected to position the object at the lateral coordinate position {Xo, Yo}. At 814, method 800 includes moving object-handling member 110 in the second lateral direction (e.g., in the X direction, as shown in FIG. 1) by a second distance selected to place the object-handling member directly above the lateral coordinate position. In some cases, the first and second distances are determined by the system controller, which then communicates the second distance to the apparatus controller 140.

[0168] FIG. 9 shows an illustrative method 900 for operating object-handling member 110 to pick various objects, such as consumable 150. Various procedures 910-928 of method 900 can be interrupted by a failure signal or stop signal depending on the success of each procedure. The operation of method 900 interfaces directly with Field Programmable Gate Array (FPGA) registers of FPGA 1000, as show in FIG. 10. If either a failure or stop signal is issued, 932 or 934 are performed to verify the failure or stop. Subsequently, method 900 bypasses the remaining procedures and finishes. In various cases, controller 140 (as shown in FIG. 4) is configured to send signals to various motors of the vacuum-operated object-handling apparatus to perform method 900.

[0169] At 910, method 900 includes moving object-handling member 110 (as shown in FIG. 1) to a Z position clear of any objects in the vicinity. After completing 910, at 912, object-handling member 110 is moved to an X position corresponding to where an object will Patent Application 003168.4560 be picked. Additionally, at 912, a valve connecting the negative pressure generating system is opened to create a negative gauge pressure within lumen 112. At 914, controller 140 moves object-handling member 110 to a Z position where the pick operation starts, which can be relatively close to the object to be picked (e.g., within a few centimeters from the object, a decimeter from the object, and the like).

[0170] At 916, a threshold for a change in gauge pressure is set by controller 140. This threshold can be recorded in memory 142 associated with controller 140 (as show n in FIG. 4) or in a register 1018 of FPGA 1000, which consists of an array of programmable logic blocks configured to perform complex combinational functions, interconnected via programmable interconnects.

[0171] At 918, a control register 1024 bit, as shown in FIG 10, is selected to allow the FPGA to monitor the gauge pressure data obtained by gauge pressure sensor 117. Another bit is selected to unmask the interrupt 1026 which sends a message to the controller 140. The control register is configured to receive gauge pressure data 1012 as it is collected in real time.

[0172] At 920, method 900 includes performing the pick move by continuously moving object-handling member 110 towards the object in the Z direction. The gauge pressure is monitored at the sample rate by the FPGA. If a change is gauge pressure is detected and is below the threshold 1020, an interrupt from the FPGA 1000 to the controller 140, is created. If no interrupt from the FPGA occurs (922, No), a failure is declared (932, true) and the objecthandling member 110 is moved to a predetermined height in the Z direction at 924.

[0173] After completing 924, at 926, a check of the negative gauge pressure is performed using gauge sensor 117 at the new predetermined height by reading FPGA register 1012. The register for holding gauge pressure values obtains the new gauge pressure value based on this check. After completing 926, at 928, object-handling member 110 is moved to a Z position that is clear of any objects. After completing 928, method 900 completes.

[0174] Logic unit 1000 can be part of controller 140 or can be located in the FPGA. It includes a PCIE host interface 1030, which represents the interface to a host computer or controller that communicates with the vacuum-operated system via the PCIE protocol. Additionally, unit 1000 includes a vacuum sensor data interface 1032, an interface through which data from gauge sensor 117 is received. The unit also features an A / D converter 1010, which converts analog signals received from the gauge sensor (if it provides analog signals) into digital data that can be processed by logic unit 1000. Patent Application 003168.4560

[0175] Logic unit 1000 includes A / D data memory 1012 for storing digital data from A / D converter 1010, and a data filter 1014, which processes raw data to filter out noise or irrelevant signals, ensuring accurate readings. A threshold offset register 1016 holds an offset value for the gauge pressure change threshold, allowing adjustments to the threshold, while the threshold register 1018 holds the gauge pressure change threshold value against which readings from gauge sensor 117 are compared.

[0176] A data comparator 1020 in logic unit 1000 is configured to compare the filtered data from gauge sensor 117 against the gauge pressure change threshold value. If the change detected by gauge sensor 117 is above the threshold, limit output interrupt generator 1026 generates an interrupt to controller 140. This interrupt signal (motor limit output 1036) stops the motor from operating the object-handling member 110.

[0177] Further, logic unit 1000 includes a status register 1022 for holding the current status of the vacuum-operated system, such as whether the vacuum level is within acceptable limits or if an interrupt has been triggered. Additionally, control register 1024 is used to configure the control parameters of the vacuum-operated system, such as setting thresholds or enabling / disabling interrupts.

[0178] In various cases, logic unit 1000 is configured to receive input from the motor sensor input 1034, which includes feedback signals from various motors of the end effector positioning system, indicating their position. This feedback is used to adjust the operation of the obj ect-handling member, process gauge pressure data from the gauge sensor, and either issue an interrupt signal to stop object-handling member 110 from moving or interface via the PCIE host interface to continue executing the movement of object-handling member 110.

[0179] In the foregoing specification, the present disclosure has been described with reference to numerous specific details that can vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the present disclosure, and what is intended by the applicants to be the scope of the present disclosure, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction.

[0180] The scope of this disclosure encompasses all changes, substitutions, variations, alterations, and modifications to the illustrative embodiments described or illustrated herein that a person having ordinary skill in the art would comprehend. The scope of this disclosure is not limited to the embodiments described or illustrated herein. Moreover, although this Patent Application 003168.4560 disclosure describes and illustrates respective embodiments herein as including particular components, elements, feature, functions, or operations, any of these embodiments can include any combination or permutation thereof described or illustrated anywhere herein that a person having ordinary skill in the art would comprehend. Furthermore, reference in the appended claims to an apparatus or system or a component of an apparatus or system being adapted to, arranged to, capable of, configured to, enabled to, operable to, or operative to perform a particular function encompasses that apparatus, system, component, whether or not it or that particular function is activated, turned on, or unlocked, as long as that apparatus, system, or component is so adapted, arranged, capable, configured, enabled, operable, or operative. Additionally, although this disclosure describes or illustrates particular embodiments as providing particular advantages, particular embodiments can provide none, some, or all of these advantages.

[0181] Herein, “or” is inclusive and not exclusive, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A or B” means “A, B, or both,” unless expressly indicated otherwise or indicated otherw ise by context. Moreover, “and” is both joint and several, unless expressly indicated otherwise or indicated otherwise by context. Therefore, herein, “A and B” means “A and B, jointly or severally.” unless expressly indicated otherwise or indicated otherwise by context.

[0182] While specific configurations are described for illustration purposes and not for limitation, the scope of this disclosure is not confined to these configurations. The disclosed subject matter can include any, all, or none of the components, elements, features, functions, or operations described in the examples herein. The dependencies or references back in the attached claims are chosen for formal reasons only. However, any subject matter resulting from a deliberate reference back to any previous claims (in particular multiple dependencies) can be claimed as well, so that any combination of claims and the features thereof are disclosed and can be claimed regardless of the dependencies chosen in the attached claims. The subject matter that can be claimed comprises not only the combinations of features as set out in the attached claims but also any other combination of features in the claims, wherein each feature mentioned in the claims can be combined with any other feature or combination of other features in the claims. Furthermore, any of the features and combinations described or depicted herein can be claimed in a separate claim and / or in any combination with any feature or combination described or depicted herein or with any of the features of the attached claims.

Claims

Patent Application003168.4560CLAIMSWhat is claimed is:

1. A vacuum-operated obj ect-handling apparatus comprising: a vacuum module; an object-handling member configured to move at least in a vertical direction, the object-handling member defining a lumen extending from a first end portion to a second end portion thereof, wherein the first end portion is fluidly connected to the vacuum module, the second end portion is open to air, and the vacuum module is configured to create a pressure differential between the lumen and the air a gauge sensor, operatively coupled to the object-handling member, and configured to determine a gauge pressure at a test location within the lumen; and an apparatus controller, operatively coupled to the object-handling member and to the gauge sensor, and configured to: execute a continuous motion of the object-handling member at least in the vertical direction towards an object; and execute a soft stop of the continuous motion when a change in the gauge pressure is below a threshold.

2. The apparatus of claim 1, wherein the apparatus controller is further configured to monitor, at a set frequency, the gauge pressure.

3. The apparatus of claim 1, wherein the object-handling member is further configured to move in a lateral direction perpendicular to the vertical direction.

4. The apparatus of claim 3, further configured to: move the object from a first location to a second location, by executing a motion of the object-handling member in the vertical direction, the lateral direction, or combination thereof; and release the object from the object-handling member at the second location by venting the lumen, thereby setting the gauge pressure to about zero or positive value.Patent Application003168.45605. The apparatus of claim 1 , wherein the object-handling member includes a vacuum end effector comprising a flexible material.

6. The apparatus of claim 5, wherein the vacuum end effector is formed from a material being one of silicon elastomer, rubber, plastic, or a combination thereof.

7. The apparatus of claim 5, wherein the vacuum end effector comprises a flat surface containing one or more holes, the one or more holes fluidly connecting the lumen with the air surrounding the object-handling member.

8. The apparatus of claim 1, further comprising a coupling configured to couple a connecting member of the object-handling member and any one of a set of vacuum end effectors, each one of the set of vacuum end effectors configured to attach to objects being handled.

9. The apparatus of claim 8, wherein at least one of the set of vacuum end effectors comprises a cylindrical shape configured to be inserted into an opening of a consumable, such that there is a sufficient seal between walls of the consumable and the cylindrical shape for maintaining a required negative gauge pressure within the consumable.

10. The apparatus of claim 1, wherein the apparatus controller is further configured to: compute a running average of the gauge pressure over a first predetermined time window; and compute the change in the gauge pressure by computing the change in the running average over a second predetermined time window.

11. The apparatus of claim 10, wherein the first predetermined time window is about 10 milliseconds.

12. The apparatus of claim 1, wherein the soft stop comprises performing a deceleration of the object-handling member by utilizing a prescribed deceleration profile characterizing a reduction of velocity of motion of the object-handling member as a function of time.Patent Application003168.456013. The apparatus of claim 12, wherein the prescribed deceleration profile is one of linear, quadratic or exponential.

14. The apparatus of claim 1, wherein the vacuum module comprises: a negative pressure-generating device; a positive pressure-generating device; and a valve system having at least a first configuration and a second configuration; wherein the valve system, in the first configuration, is arranged to fluidly connect the lumen with the negative pressure-generating device, and in the second configuration, is arranged to fluidly connect the lumen with the positive pressure-generating device, such that: when the valve system is in the first configuration, a negative gauge pressure is created in the lumen by operating the negative pressure-generating device; and when the valve system is in the second configuration, a positive gauge pressure is created in the lumen by operating the positive pressure-generating device.

15. The apparatus of claim 14, wherein the vacuum module further comprises a negative pressure chamber being maintained at a negative gauge pressure by fluidly connecting the negative pressure-generating device to the negative pressure chamber, wherein the vacuum chamber can be configured to fluidly connect to the lumen.

16. The apparatus of claim 15, wherein the apparatus controller is configured to fluidly couple the negative pressure chamber to the lumen when the negative pressure-generating device is disabled.

17. The apparatus of claim 16, the valve system further having a third configuration, such that, when the valve system is in the third configuration, the lumen is fluidly coupled to the negative pressure chamber.

18. The apparatus of claim 16, wherein the vacuum module further comprises a positive pressure chamber being maintained at a positive gauge pressure by fluidly connecting the positive pressure-generating device to the positive pressure chamber, wherein the positive pressure chamber can be configured to fluidly connect to the lumen.Patent Application003168.456019. The apparatus of claim 18, the valve system further having a fourth configuration, such that, when the valve system is in the fourth configuration, the lumen is fluidly coupled to the positive pressure chamber.

20. The apparatus of claim 1, wherein the apparatus controller is further configured to: determine the change in the gauge pressure as the object-handling member executes the continuous motion toward the object.

21. The apparatus of claim 1, wherein the lumen of the object-handling member is fluidly connected to the vacuum module via a flexible channel configured to fluidly connect the lumen and the vacuum module, for different vertical and lateral positions of the object-handling member relative to the vacuum module.

22. The apparatus of claim 21, wherein the vacuum module comprises: a negative pressure-generating device; a positive pressure-generating device; and a valve system; and wherein the flexible channel is arranged to connect the lumen to the valve system, and wherein the valve system is operable to: couple the object-handling member to the positive pressure-generating device when the valve system is in a first configuration; and couple the object-handling member to the negative pressure-generating device when the valve system is in a second configuration.

23. A system for handling objects, the system comprising: a tray configured to contain at least one object, the tray configured to move at least along a straight line in a first lateral direction; a vacuum-operated object-handling apparatus comprising: a vacuum module; an object-handling member configured to move at least in a vertical direction, the object-handling member defining a lumen extending from a first end portion to a second end portion, wherein the first end portion is fluidly connected to the vacuum module, the secondPatent Application003168.4560 end portion is open to air, and the vacuum module is configured to a create pressure differential between the lumen and the air; a gauge sensor, operatively coupled to the object-handling member, and configured to determine a gauge pressure at a test location within the lumen; and an apparatus controller, operatively coupled to the object-handling member and to the gauge sensor, and configured to: execute a continuous motion of the object-handling member at least in the vertical direction towards an object; and execute a soft stop of the continuous motion when a change in the gauge pressure is below a threshold.

24. The system of claim 23, wherein the object-handling member is further configured to move in a second lateral direction perpendicular to the vertical direction and the first lateral direction, the system further comprising a system controller configured to: determine a lateral coordinate position at which the object is located; move the tray in the first lateral direction by a first distance, the first distance being selected such that the object is located at the lateral coordinate position; and move the object-handling member in the second lateral direction by a second distance, the second distance being selected such that the object-handling member is placed directly above the lateral coordinate position.

25. The system of claim 24. wherein the first distance and the second distance are determined by the system controller, and wherein the system controller is configured to communicate the second distance to the apparatus controller.

26. The system of claim 23, wherein the object-handling member comprises a connecting member coupled to a vacuum end effector via an end effector coupling, and wherein the vacuum end effector is selected from a set of vacuum end effectors, each one of the set of vacuum end effectors configured to handle a particular object from a set of objects.

27. The system of claim 26, wherein the set of objects comprises tubular objects, tip objects, and tray objects.Patent Application003168.456028. The system of claim 26, wherein the apparatus controller is further configured to: automatically decouple the vacuum end effector via the end effector coupling; and automatically couple the vacuum end effector via the end effector coupling.

29. The system of claim 28, wherein the end effector coupling comprises a magnetic coupling using an electromagnet.

30. The system of claim 23, further comprising: a track extending in a second lateral direction; a track sliding device for moving along the second lateral direction; and a coupling device for coupling the object-handling member to the track sliding device.

31. A method of operating a vacuum-operated object-handling apparatus including an object-handling member configured to move at least in a vertical direction and defining a lumen extending from a first end portion to a second end portion open to air, the method comprising: applying a vacuum to the first end portion of the lumen to thereby create a pressure differential between the lumen and the air; determining a gauge pressure at a test location within the lumen: executing a continuous motion of the object-handling member at least in the vertical direction towards an object; monitoring, at a set frequency, a change in the gauge pressure; and executing a soft stop of the continuous motion when the change in the gauge pressure is below a threshold.

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