(en)The present invention is directed to a system and method for load balancing specimen containers between a plurality of automated detection apparatuses. The method may include receiving a specimen container at a container pick-up station in a first automated detection apparatus; determining loading ability, transfer status, and cell availability of the first automated detection apparatus and one or more downstream automated detection apparatuses; and transferring the specimen container from the first automated detection apparatus to a downstream automated detection apparatus when a first ratio of effective available cell count to effective capacity in the first automated detection apparatus is less than a second ratio of total effective available cell count to total effective capacity of a sum of the first automated detection apparatus and the one or more downstream automated detection apparatuses.

1.ApplicationNumber: US-201715606133-A
1.PublishNumber: US-2017343993-A1
2.Date Publish: 20171130
3.Inventor: VIVET THIERRY
VINCENT WARREN

4.Inventor Harmonized: VIVET THIERRY(US)
VINCENT WARREN(US)

5.Country: US
6.Claims:
(en)The present invention is directed to a system and method for load balancing specimen containers between a plurality of automated detection apparatuses. The method may include receiving a specimen container at a container pick-up station in a first automated detection apparatus; determining loading ability, transfer status, and cell availability of the first automated detection apparatus and one or more downstream automated detection apparatuses; and transferring the specimen container from the first automated detection apparatus to a downstream automated detection apparatus when a first ratio of effective available cell count to effective capacity in the first automated detection apparatus is less than a second ratio of total effective available cell count to total effective capacity of a sum of the first automated detection apparatus and the one or more downstream automated detection apparatuses.

7.Description:
(en)FIELD OF THE INVENTION
The present invention is directed to a system and method for loading balancing specimen containers between a plurality of automated detection apparatuses.
BACKGROUND OF THE INVENTION
The detection of pathogenic microorganisms in biological fluids should be performed in the shortest possible time, in particular in the case of septicemia for which the mortality remains high in spite of the broad range of antibiotics which are available to doctors. The presence of biologically active agents such as a microorganism in a patient's body fluid, especially blood, is generally determined using blood culture bottles. A small quantity of blood is injected through an enclosing rubber septum into a sterile bottle containing a culture medium, and the bottle is then incubated at 37° C. and monitored for microorganism growth.
Instruments currently exist on the market in the U.S. that detect the growth of a microorganism in a biological sample. One such instrument is the BacT/ALERT® 3D instrument of the present assignee bioMerieux, Inc. The instrument receives a blood culture bottle containing a blood sample, e.g., from a human patient. The instrument incubates the bottle and periodically during incubation an optical detection unit in the incubator analyzes a colorimetric sensor incorporated into the bottle to detect whether microbial growth has occurred within the bottle. The optical detection unit, bottles, and sensors are described in the patent literature, see U.S. Pat. Nos. 4,945,060; 5,094,955; 5,162,229; 5,164,796; 5,217,876; 5,795,773; and 5,856,175, the entire content of each of which is incorporated by reference herein. Other prior art of interest relating generally to the detection of microorganisms in a biological sample includes the following patents: U.S. Pat. No. 5,770,394, U.S. Pat. No. 5,518,923; U.S. Pat. No. 5,498,543, U.S. 5,432,061, U.S. Pat. No. 5,371,016, U.S. Pat. No. 5,397,709, U.S. Pat. No. 5,344,417 and its continuation U.S. Pat. No. 5,374,264, U.S. Pat. No. 6,709,857; and U.S. Pat. No. 7,211,430, the entire content of each of which is incorporated by reference herein.
SUMMARY OF THE INVENTION
An automated system and instrument architecture is described below that provides for automated detection of the presence of a microbial agent (e.g., a microorganism) in a test sample contained within a specimen container. In one embodiment, the automated detection instrument of the present invention is an automated culture instrument for detecting the growth of a microbial agent contained in, or suspected of being contained in, a test sample, wherein the test sample is cultured within a specimen container, e.g., a blood culture bottle. In some embodiments, a system and method for load balancing specimen containers between a plurality of automated detection apparatuses is provided.
The automated detection system of the present invention receives a specimen container (e.g., a blood culture bottle), containing a culture media and a test sample (e.g., a blood sample), suspected of containing a microorganism therein. The detection system comprises a housing, a holding structure and/or agitation means for holding and/or agitating the specimen container to promote or enhance microorganism growth therein, and optionally may further contain one or more heating means to provide a heated enclosure or incubation chamber. The automated detection system also comprises one or more detection units that determine whether a container is positive for the presence of a microbial agent in the test sample. The detection unit may include the features of U.S. Pat. Nos. 4,945,060; 5,094,955; 5,162,229; 5,164,796; 5,217,876; 5,795,773; and 5,856,175, or it may include other technology for detecting the presence of a microbial agent in the test sample. Containers (e.g., bottles) in which a microbial agent is present are termed “positive” herein.
In a first aspect, a method for load balancing between a plurality of automated detection apparatuses is provided. In some embodiments, the method includes receiving a specimen container at a container pick-up station in a first automated detection apparatus; determining a loading ability of the first automated detection apparatus; determining a loading ability of one or more downstream automated detection apparatuses; determining a transfer status of the first automated detection apparatus; determining a transfer status of the one or more downstream automated detection apparatuses; determining cell availability in the first automated detection apparatus and in the one or more downstream automated detection apparatuses; and transferring the specimen container from the first automated detection apparatus to a downstream automated detection apparatus when a first ratio of effective available cell count to effective capacity in the first automated detection apparatus is less than a second ratio of total effective available cell count to total effective capacity of a sum of the first automated detection apparatus and the one or more downstream automated detection apparatuses.
In some embodiments, the method includes loading the specimen container into the first automated detection apparatus when the first ratio is greater than or equal to the second ratio.
In further embodiments, the method includes assigning a transfer status to the first automated detection apparatus and/or the one of more downstream automated detection apparatuses, the transfer status selected from the group consisting of active, disabled, load-only, and pass through.
In one embodiment, an automated detection apparatus having an active status is determined to be capable of loading a specimen container into a well of the automated detection apparatus and is determined to be capable of transferring to and from the automated detection apparatus.
In another embodiment, an automated detection apparatus having a disabled status is determined to be incapable of loading a specimen container into a well of the automated detection apparatus and is determined to be incapable of transferring to and from the automated detection apparatus.
In a further embodiment, an automated detection apparatus having a load-only status is determined to be capable of loading a specimen container into a well of the automated detection apparatus and is determined to be incapable of transferring to a downstream automated detection apparatus.
In a still further embodiment, an automated detection apparatus having a pass through status is determined to be incapable of loading a specimen container into a well of the automated detection apparatus and is determined to be capable of transferring to and from the automated detection apparatus.
In some embodiments, the method includes transferring the specimen container from the first automated detection apparatus to a downstream automated detection apparatus to reduce overall temperature variation within the automated detection apparatus and the one or more downstream automated detection apparatuses.
In one embodiment, the method includes triggering an alarm when the cell availability in the first automated detection apparatus and in the one or more downstream automated detection apparatuses is determined to be zero. In some embodiments, the method includes overriding the transfer to the one or more downstream automated detection apparatuses when the cell availability in the first automated detection apparatus is determined to be within 5% of the total capacity of the first automated detection apparatus.
In a second aspect, a non-transitory computer-readable medium for load balancing between a plurality of automated detection apparatuses with instructions stored thereon in provided. In an embodiment, the instructions, when executed by a processor, perform the steps comprising: receiving a specimen container at a container pick-up station in a first automated detection apparatus; determining a loading ability of the first automated detection apparatus; determining a loading ability of one or more downstream automated detection apparatuses; determining a transfer status of the first automated detection apparatus; determining a transfer status of the one or more downstream automated detection apparatuses; determining cell availability in the first automated detection apparatus and in the one or more downstream automated detection apparatuses; and transferring the specimen container from the first automated detection apparatus to a downstream automated detection apparatus when a first ratio of effective available cell count to effective capacity in the first automated detection apparatus is less than a second ratio of total effective available cell count to total effective capacity of a sum of the first automated detection apparatus and the one or more downstream automated detection apparatuses.
In some embodiments, the instructions further perform the step of loading the specimen container into the first automated detection apparatus when the first ratio is greater than or equal to the second ratio.
In some embodiments, the instructions, when executed by a processor, further perform the step of assigning a transfer status to the first automated detection apparatus and/or the one of more downstream automated detection apparatuses, the transfer status selected from the group consisting of active, disabled, load-only, and pass through.
In some embodiments, the instructions, when executed by a processor, further perform the step of triggering an alarm when the cell availability in the first automated detection apparatus and in the one or more downstream automated detection apparatuses is determined to be zero.
In some embodiments, the instructions, when executed by a processor, further perform the step of overriding the transfer to the one or more downstream automated detection apparatuses when the cell availability in the first automated detection apparatus is determined to be within 5% of the total capacity of the first automated detection apparatus.



BRIEF DESCRIPTION OF THE FIGURES
The various inventive aspects will become more apparent upon reading the following detailed description of the various embodiments along with the appended drawings, in which:
FIG. 1 is a perspective view of an automated system for rapid non-invasive detection of a microbial agent in a test sample. As shown, the system includes an automated loading mechanism.
FIG. 2 is a perspective view of the detection system of FIG. 1 , showing a close-up view of the automated loading mechanism.
FIG. 3 is a perspective view of the detection system of FIG. 1 , which shows an automated loading mechanism and a lower drawer that opens to reveal a waste container for containers that tested negative for presence of a microbial agent.
FIG. 4 is a side view of one of the specimen containers processed in the detection system of FIG. 1-3 . While the detection container can take a variety of forms, in one embodiment it is configured as a blood culture bottle.
FIG. 5A is a side elevation view of one configuration of the detection system of FIG. 1 .
FIG. 5B is a perspective view of the detection system shown in FIG. 5A , with the upper and lower doors open showing the interior chambers and racks for holding multiple containers of the type shown in FIG. 4 .
FIG. 6 is a perspective view of the transfer mechanism shown in FIGS. 5A and 5B , showing the horizontal and vertical support rails. Also shown are first and second rotational mechanisms, which are operable to rotate the transfer mechanism about one or more axes.
FIG. 7A is a perspective view of the robotic head and vertical support rail shown in FIGS. 5A and 5B . As shown in FIG. 7A , the robotic head is position in a vertical orientation, such that a specimen container held within the robotic head is also in a vertical orientation.
FIG. 7B is another perspective view of the robotic head and vertical support rail shown in FIGS. 5A and 5B . As shown in FIG. 7B , the robotic head is positioned in a horizontal orientation, such that the container held within the robotic head is also in a horizontal orientation.
FIGS. 8A-C shows a time-elapsed loading of a specimen container into the holding chamber of the robotic head shown in FIGS. 5A and 5B . As shown in FIG. 8A , the gripping mechanism grips the top or cap of the container. FIG. 8B shows the container in an intermediate position in the loading process. FIG. 8B , shows the container after being loaded into the robotic head.
FIGS. 9A and 9B are perspective and side views, respectively, of an alternative configuration of the detection system of FIGS. 1-3 and 5A-5B , with the upper and lower doors open showing an alternative configuration of the container holding structures. In the embodiment of FIGS. 9A and 9B , the racks are arranged in a drum or cylinder-type configuration.
FIG. 10 is a perspective view of another configuration of the automated loading mechanism, showing a first conveyor belt operable in a horizontal plane and a second conveyor belt operable in a vertical plane.
FIG. 11 is a perspective view of yet another configuration of the automated loading mechanism, showing a first conveyor belt operable in a horizontal plane and a second conveyor belt having a plurality of paddles and operable in a vertical plane.
FIG. 12 is a perspective view of a casing and cover provided with an automated loading mechanism.
FIG. 13 is a perspective view of one embodiment of an automated loading mechanism shown isolated from the detection system. In accordance with this embodiment, the automated loading mechanism comprises a loading station or area, a transport mechanism and an entrance location, for the fully automated loading of a specimen container. A portion of one side of the loading area has been removed to show additional details of the automated loading mechanism of this embodiment.
FIG. 14 is another perspective view of the automated loading mechanism shown in FIG. 14 . The container loading area is shown as a see through feature to reveal other features of the automated loading mechanism, as described herein.
FIG. 15 is a close up perspective view of the drum-like loading mechanism, vertical chute, locating device and system transfer device in FIG. 14 . The drum-like loading mechanism, vertical chute, locating device and system transfer device are shown isolated from the detection system.
FIG. 16 is a cross-sectional view of the automated loading mechanism shown in FIGS. 14-15 . More specifically, FIG. 16 is a cross-sectional view of the drum-like loading mechanism and vertical chute showing a specimen container falling through the chute. As shown in FIG. 16 , the top or cap of the specimen container is held in place briefly by the tapered ledge as the bottom of the container falls through the chute, thereby up-righting the specimen container.
FIG. 17 is a perspective view of the automated detection apparatus comprising the automated loading mechanism shown in FIG. 14 . The container loading area of the automated loading mechanism is shown in a user accessible location on the front of an automated system for rapid non-invasive detection of a microbial agent. The automated detection system and the container loading area are shown with side panels removed and/or as see through features to reveal other features, as described herein.
FIG. 18 is a perspective view of the automated detection apparatus comprising an alternative loading mechanism. The container loading area of the automated loading mechanism is shown in a user accessible location on the front of an automated system for rapid non-invasive detection of a microbial agent. The automated detection system and the container loading area are shown with side panels removed and/or as see through features to reveal other features, as described herein.
FIG. 19 is a side view of the lower portion of the automated system for rapid non-invasive detection of a microbial agent shown in FIG. 17 . The automated detection system is shown with side panel removed to reveal other features of the system, as described herein.
FIG. 20 is a perspective view of the holding structure and automated transfer mechanism shown in FIGS. 17-19 . As shown, in this embodiment, the automated transfer mechanism comprises a lower horizontal support, a vertical support, a pivot plate and a robotic head for transferring a specimen container within a detection apparatus. For clarity, the holding structure and automated transfer mechanism are shown isolated from the detection apparatus.
FIGS. 21A-B are perspective views of the pivot plate and robotic head of the automated transfer mechanism shown in FIG. 20 . The robotic head is shown with a cross-sectional view of the gripping mechanism and specimen container to reveal the features of the gripping mechanism. As shown in FIG. 21A , the robotic head is located at a first end of the pivot plated and in a horizontal orientation, such that the specimen container is also orientated in a horizontal orientation. In FIG. 21B , the robotic head is shown located at a second end of the pivot plate and in a vertical orientation, such that the specimen container is also orientated in a vertical orientation.
FIG. 22 is a perspective view of an alternative configuration of the automated detection apparatus showing a user interface, a status screen, a locator device cover and two positive container ports.
FIG. 23 is a perspective view showing another design configuration of the detection apparatus. As shown in FIG. 23 , the detection system comprises a first detection apparatus and a second detection instrument.
FIG. 24 is a perspective view of yet another embodiment of the automated detection system. As shown, the automated detection system comprises a first detection apparatus having an automated loading mechanism and a second or down-stream detection apparatus linked or “daisy-chained” to the first detection apparatus, as described herein.
FIGS. 25A-C show a time-elapsed pusher arm mechanism for pushing a specimen container from a first detection apparatus to a second or downstream detection apparatus. FIGS. 25D-E show a system for transferring a specimen contained from a first detection apparatus to a second or downstream detection apparatus.
FIG. 26 shows a perspective view of the holding structure and agitation assembly shown isolated from the detection system.
FIG. 27A is a perspective view of a rack holding structure and retention feature for holding a specimen container securely within the rack holding structure.
FIG. 27B shows a cross-sectional view of the rack holding structure and retention feature shown in FIG. 27A .
FIG. 27C is a top cross-sectional view of the rack holding structure and retention feature of FIG. 27A , showing a schematic representation of a canted coiled spring.
FIG. 28A-B show first and second perspective views of a carrier for carrying a plurality of specimen containers to the detection apparatus. As shown, the carrier comprises a plurality of holding wells for holding a plurality of specimen containers. FIG. 28A also shows two opposed gripping features or handles and a release mechanism for releasing the plurality of specimen containers at the loading station, as described herein.
FIG. 29 shows a perspective view of another possible configuration for the detection system. As shown in FIG. 29 , the detection system includes a release mechanism for releasing one or more specimen containers from the carrier shown in FIGS. 28A-B .
FIG. 30 is a flow chart showing the steps performed in the operation of the detection system.
FIG. 31 is a flow chart showing the steps performed in the operation of a method for transferring specimen containers between automated microbial detection apparatuses.
FIG. 32 is a flow chart showing the steps performed in the operation of a method for loading balancing specimen containers between automated detection apparatuses.



DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. It will be appreciated that although discussed with respect to a certain embodiment, features or operation of one embodiment can apply to others.
In the drawings, the thickness of lines, layers, features, components and/or regions may be exaggerated for clarity. In addition, the sequence of operations (or steps) is not limited to the order presented in the claims unless specifically indicated otherwise.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. While the term “comprising” may be used herein, it should be understood that the objects referred to as “comprising” elements may also “consist of” or “consist essentially of” the elements. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Like numbers refer to like elements throughout. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.
The term “automatically” means that the operation can be substantially, and typically entirely, carried out without human or manual input, and is typically programmatically directed or carried out. The term “electronically” includes both wireless and wired connections between components. The term “about” means that the recited parameter or value can vary by between about +/−20%.
An automated system or instrument for non-invasive detection of the presence of a microbial agent (e.g., a microorganism) in a test sample contained within a sample container, e.g., a culture bottle, is described herein. Further, systems and methods for efficiently and safely load balancing specimen containers between a plurality of automated detection apparatuses are provided. One embodiment of the automated system or instrument is described herein in conjunction with FIGS. 1-8C . Other possible embodiments and design alternatives are shown in conjunction with FIGS. 9A-30 , and described herein. The automated system can include one or more of the following features: (1) a housing, enclosing an interior chamber; (2) an automated loading mechanism for loading one or more containers to an entrance location and/or into the interior chamber of the system; (3) an automated container management mechanism or locator device for moving or locating a container among various work-flow stations within the system; (4) an automated transfer mechanism, for transfer of a container within the system; (5) one or more container holding structures for holding a plurality of specimen containers, optionally provided with an agitation assembly; (6) a detection unit for detection of microbial growth; and/or (7) a mechanism for automated unloading of a specimen container from the system. In order to better appreciate how the illustrated embodiment of the detection system operate, this specification may describe the automated detection apparatus in the context of a particular detection instrument (a blood culture instrument) and specimen container (a blood culture bottle). However, persons skilled in the art will readily appreciate that the detection apparatus can be practiced in other embodiments, that variations from the specific embodiments disclosed herein can be arrived at to suit particular implementations, and that therefore the present description of a preferred embodiment and best mode for practicing the invention is provided by way of illustration and not limitation.
System Overview
An automated detection system 100 (for example, as illustrated in FIGS. 1-3 and 5A-5B ) is described herein that provides a new architecture and method for automated detection of a microbial agent (e.g., a microorganism) that may be present in a test sample or specimen sample. In general, any known test sample (e.g., a biological sample) can be used. For example, the test sample can be a clinical or non-clinical sample suspected of containing one or more microbial agents. Clinical samples, such as a bodily fluid, include, but are not limited to, blood, serum, plasma, blood fractions, joint fluid, urine, semen, saliva, feces, cerebrospinal fluid, gastric contents, vaginal secretions, tissue homogenates, bone marrow aspirates, bone homogenates, sputum, aspirates, swabs and swab rinsates, other body fluids, and the like. Non-clinical samples that may be tested include, but not limited to, foodstuffs, beverages, pharmaceuticals, cosmetics, water (e.g., drinking water, non-potable water, and waste water), seawater ballasts, air, soil, sewage, plant material (e.g., seeds, leaves, stems, roots, flowers, fruit), blood products (e.g., platelets, serum, plasma, white blood cell fractions, etc.), donor organ or tissue samples, biowarfare samples, and the like. In one embodiment, the biological sample tested is a blood sample.
Referring now to the Figures, several configurations are possible for the detection system 100 . As shown, for example, in FIGS. 1-3 and 5A-5B , the automated detection system 100 comprises a housing 102 and one or more automated mechanisms for loading (see, e.g., 200 , FIG. 1 ), moving or locating (not shown), transferring (see, e.g., 650 , FIGS. 5A-5B ), agitating (not shown) and/or unloading of specimen containers 500 within or from the detection system 100 . The housing 102 comprises front and back panels 104 A and 104 B, opposing side panels (e.g., left-side and right-side panels) 106 A and 106 B, a top or roof panel 108 A and a bottom or floor panel 108 B, which form an enclosure, enclosing an interior chamber 620 (see, e.g., FIGS. 5A-5B ) of the detection system 100 . In one embodiment, the interior chamber 620 of the detection system 100 is a climate-controlled chamber (e.g., a temperature-controlled incubation chamber wherein the temperature is maintained at approximately 37° C.) to promote or enhance microbial growth. As shown in FIGS. 1-3 , the housing also may include a first port or container entrance location 110 , a second port or misread/error location 120 , a third port or positive container exit location 130 , a lower access panel 140 ( FIG. 1 ) or drawer 142 ( FIG. 3 ), and/or a user interface display 150 . The lower access panel 140 or drawer 142 may include a handle 144 . Also as shown in FIG. 1 , the housing 102 may also comprise upper and lower sections 160 and 170 , optionally each comprising an operable door (i.e., upper and lower doors) 162 and 172 (see, e.g., FIG. 5B ). The upper door 162 and lower door 172 are operable to allow access to the interior chamber 620 of the detection system 100 . However, as one of skill in the art would appreciate other design configurations are possible. For example, in another possible embodiment, the entire front panel may comprise a single operable door (not shown).
In one design possibility, as shown for example in FIGS. 1-3 , the lower section 170 may have a larger profile or footprint than the upper section 160 . In accordance with this embodiment the housing of the larger lower section 170 forms a shelf 180 on a top surface of the lower section 170 and adjacent to or in front of the upper section 160 . This shelf 180 may provide a user workstation and/or workflow access points to the detection system 100 . Furthermore, the shelf 180 may comprise an automated loading means or mechanism 200 . The shelf 180 may further provide access locations for the first port or container entrance location 110 , the second port or misread/error location 120 , and the third port or positive container exit location 130 .
In one embodiment, as shown for example in FIGS. 1-3 and 5A-5B , the detection system 100 may comprise an automated loading mechanism 200 , for the automated loading of a specimen container 500 into the detection system 100 . The automated loading mechanism 200 may comprise a container loading station or area 202 , a transport mechanism 204 and a first port or container entrance location 110 . In operation, a user or technician can place one or more specimen containers 500 (see, e.g., FIG. 4 ) at the container loading station or area 202 . A transport mechanism 204 , for example, a conveyor belt 206 , will transport the specimen container to the first port or container entrance location 110 , and in some designs subsequently through the entrance location 110 and into the detection system 100 , thereby loading the container into the system. The automated loading mechanism 200 is described in greater detail herein.
As one of skill in the art would appreciate, other designs may be employed for the automated loading mechanism and are described elsewhere herein. For example, alternative automated loading mechanisms are shown in FIGS. 10-16 . In one embodiment, as shown in FIGS. 13-16 , and as described in greater detail herein, the detection system 100 may employ a container loading area or reservoir 302 and a drum-like loading device 308 for the automated loading of a specimen container into the detection system 100 .
In another embodiment, as shown for example in FIGS. 14-15 and 18 , the automated detection system 100 may contain one or more work-flow stations 404 for obtaining one or more measurements, readings, scans and/or images of a specimen container, thereby providing information, such as, container type, container lot number, container expiration date, patient information, sample type, test type, fill level, weight measurement, etc. Furthermore, the one or more work-flow stations 404 may comprise one or more container management stations, such as, a container pick-up station or a container transfer station. For example, the automated detection system may contain one or more of the following work-flow stations: (1) a bar code reading station; (2) a container scanning stations; (3) a container imaging station; (4) a container weighing station; (5) container pick-up station; and/or (6) a container transfer station. In accordance with this embodiment, the detection system 100 may further have a container management means or container locator device 400 , as shown, for example, in FIGS. 13-15, 18 and 24 . In operation, the container management device or locator device 400 , operates to move or otherwise locate a specimen container 500 to one or more work-flow stations 404 . In one design configuration, one or more of the work-flow stations are included within the housing 102 of the detection system 100 . In one embodiment, as best shown in FIGS. 14-15 , the drum or drum-like loading device 308 and vertically orientated chute 332 of automated loading mechanism 300 can operated to deposit or place a specimen container into a locator well 402 , as described elsewhere herein. In another embodiment, as best shown, in FIGS. 18 and 24 , the transport mechanism 204 , or conveyor belt 206 , of automated loading mechanism 200 can operate to deposit or place a specimen container into a locator well 402 , as described elsewhere herein. The detection system 100 may further comprise one or more guide rails (not shown) to guide the specimen container into the locator well 402 . In accordance with both of these embodiments, the container management device or locating device 400 can then rotate to move or locate the specimen container among various work-flow stations 404 within the system, such as for example, a bar code reading station, a container scanning stations, a container imaging station, a container weighing station, container pick-up station, and/or a container transfer station. The container management device or locator device 400 is described in greater detail herein.
As shown, for example, in FIGS. 5A-8C the detection system 100 may also comprise an automated transfer means or mechanism 650 for transferring the specimen containers 500 within the housing 102 of the detection system 100 . For example, the transfer mechanism 650 may transfer the specimen container 500 from an entrance location or port 110 (see, e.g., FIGS. 1-3 ), into the interior chamber 620 of the detection system 100 , and place the container 500 into one of the receiving structures or wells 602 contained in one of a plurality of holding structures or racks 600 . In another embodiment, the transfer mechanism 650 may also be used to rearrange, transfer or otherwise manage specimen containers 500 within the system. For example, in one embodiment, the transfer mechanism 650 can be used to transfer a specimen container 500 , detected as positive for microbial growth (referred to herein as a “positive” container), from the holding structure or rack 600 to a positive container location, such as a positive container exit location or port 130 (see, e.g., FIG. 1 ) where a user or technician can easily remove the positive container 500 from the detection system 100 . In another embodiment, the transfer mechanism 650 can be used to transfer a container 500 determined as negative for microbial growth after a designated time has passed (referred to herein as a “negative” container), from the holding structure or rack 600 to a negative container location within the system (e.g., a negative container waste bin 146 (see, e.g., FIG. 1 )) where a user or technician can easily access the waste bin 146 for removal and disposal of the container 500 . As one of skill in the art would appreciate, other designs may be employed for the automated transfer mechanism and are described elsewhere herein. For example, another design configuration is described herein in conjunction with FIGS. 17-21B .
The detection system 100 will also include a means for detecting growth (e.g., a detection unit) in the specimen containers 500 (see, e.g., FIG. 27 ). In general, any known means in the art for detecting microbial growth in a container can be used. For example, each holding station or rack 600 may contain a linear scanning optical system that has the capability of non-invasive monitoring of microorganism growth in each specimen container 500 . In one embodiment, the optical system can interrogate a sensor (e.g., a Liquid Emulsion Sensor (LES) sensor) 514 (see, e.g., FIG. 4 ) in the containers 500 , thereby detecting for microorganism growth within the container.
The detection system 100 may also include an automated unloading mechanism for the unloading of “positive” and/or “negative” specimen containers 500 . This automated unloading mechanism can operate to ensure that once a “positive” or “negative” reading has been made for each specimen container 500 , the container 500 is removed from the container receiving structures or wells 602 (see, e.g., FIGS. SA and 5 B), making room for another container to be loaded into the detection system 100 , thereby increasing system through-put.
Specimen Container
The specimen container 500 , shown for example in FIGS. 4 and 27B , and other figures, is shown in the form of a standard culture bottle (e.g., a blood culture bottle). However, the description of a culture bottle (e.g., a blood culture bottle) is offered by way of example and not limitation. As shown in FIG. 4 , the specimen container 500 comprises a top portion 502 , a body 504 , and a base 506 . The container 500 may include a bar code label 508 for automated reading of the container 500 within either the detection system or off-line equipment. As shown in FIGS. 4 and 27B , the top portion 502 of the container 500 typically comprises a narrow portion or neck 510 through which an opening 516 extends to provide communication with the interior chamber 518 of the container. As shown in FIG. 27B , the container also includes a closure device 512 (e.g., a stopper), optionally having a pierceable septum and may also have a sensor 514 (e.g., an LES sensor) formed or placed in the bottom of the container 500 for purposes of colorimetric detection of the presence of microbial growth in the container 500 . The configuration of the container 500 is not particular important and the inventive system and methods can be adapted to a variety of containers designed for culturing a test sample (e.g., a biological test sample). Containers 500 of the type shown in FIGS. 4 and 27B are well known in the art and described in the patent literature cited in the Background section of this document.
In one embodiment, the specimen containers 500 are inoculated with a test sample (e.g., a clinical or non-clinical biological sample) and are loaded/unloaded into/out of the detection system 100 . The container 500 may further comprise a growth or culture medium (not shown) for promoting and/or enhancing microbial or microorganism growth. The use of a growth or culture media (or medium) for the cultivation of microorganisms is well known. A suitable growth or culture medium provides the proper nutritional and environmental conditions for growth of microorganisms and should contain all the nutrients required by the microorganism which is to be cultivated in the specimen container 500 . After a sufficient time interval to allow natural amplification of microorganisms (this time interval varies from species to species), the container 500 is tested within the detection system 100 for the presence of microbial or microorganism growth. The testing may occur continuously or on a periodic basis so that the container can be determined as positive for microorganism growth as soon as possible.
In one embodiment, once a container 500 is detected as positive in the detection system 100 , the system will notify the operator through an indicator 190 (e.g., a visual prompt), and/or via a notification at the user interface display 150 , or by other means.
Automated Loading Means or Mechanism
The detection system 100 may include a means or mechanism for automated loading of a specimen container 500 into the detection system 100 . In one embodiment, as shown for example in FIGS. 1-3 and 5A-5B , the automated loading mechanism 200 may comprise a container loading station or area 202 , a transport mechanism 204 and an entrance location or port 110 . However, as would be appreciated by one of skill in the art, the automated loading mechanism can take on many different configurations. For example, another design configuration of an automated loading mechanism 300 is described herein in conjunction with FIGS. 13-16 . The various design configurations described herein are by way of illustration and not limitation. The automated loading mechanisms shown herein (e.g., FIGS. 1-3, 5A-5B and 13-16 ) are shown schematically and the parts are not to scale.
A user or technician can transport one or more specimen containers 500 to the detection system 100 by any known means and place the containers 500 at a container loading station or area 202 . For example, in one embodiment, a user or technician can use a carrier designed to transport a plurality of specimen containers to the loading station or area 202 of the detection system 100 .
One possible carrier design is shown in FIGS. 28A and 28B . As shown in FIGS. 28A and 28B , the carrier 350 comprises a body 351 having top and bottom surfaces 352 A and 352 B, respectively, front and back surfaces 354 A and 354 B, respectively, opposing side surfaces 356 A and 356 B (e.g., a right side surface and left side surface), respectively, and a pair of opposing user handles 358 A and 358 B, attached to said opposing side surfaces 356 A, 356 B. The body further comprises a plurality of through holes 360 , each configured to hold a single specimen container 500 therein. The body 351 may also comprise a slide plate 362 operable within a slide joint 364 to slide back-and-forth (see, e.g., arrow 366 in FIG. 28A ) between a “closed” position, to retain the specimen containers 500 loaded within the carrier 350 , and an “open” position, to release the specimen containers 500 from the carrier 350 , and deposit them onto or into an automated loading mechanism. The slide joint 364 may further comprise a spring, or like means, for locking the slide plate 362 in the “closed” position during transport by a user to a detection system.
As shown in FIGS. 28A-29 , the carrier 350 may further comprise a pair of alignment arms 368 A and 368 B and a release tab 370 operable with a release mechanism 372 for releasing the specimen containers 500 at an automated loading mechanism 200 of a detection system 100 . The release mechanism 372 comprises a pair of slots 374 that correspond to the pair of alignment arms 368 A and 368 B, to ensure the carrier 350 is properly aligned at the loading station or area 202 for depositing the specimen containers 500 , and a release bar 376 . In operation, a technician transports a carrier 350 , containing one or more specimen containers 500 , to the automated loading mechanism 200 and presses the carrier 350 against the release bar 376 , with the alignment arms 368 A and 368 B aligned with the corresponding slots 374 of the release mechanism 372 . By pressing the carrier 350 against the release bar 376 , the release tab 370 is pushed in or depressed, thereby moving the slide plate 362 to the “open” position and allowing the specimen containers 500 to fall out of the through holes 360 and onto the loading station or area 202 . The technician can then lift the carrier 350 upward until the carrier body 351 and plurality of through holes 360 clear the specimen containers 500 , thereby depositing the containers at the automated loading mechanism 200 for automated loading into the detection system 100 . As one of skill in the art would appreciate other design configurations are possible.
As shown in FIGS. 1-3 , the loading station or area 202 is typically an easily accessible location or area of the automated loading mechanism 200 where a user or technician can place one or more specimen containers 500 for loading into the detection system 100 . Once at the loading station 202 , the containers 500 will be transported, using a transport mechanism 204 , from the loading station or area 202 to an entrance location or port 110 , and subsequently through the entrance location or port 110 and into the detection system 100 . Accordingly, a user or technician can simply place one or more specimen containers 500 at the loading station or area 202 and walk away, while the containers 500 are automatically loaded into the detection system 100 . Once the specimen containers 500 have been transported into the system, they can be moved to one or more work-flow stations using a container management device or locator device, and/or transferred to a holding structure or rack, as described elsewhere herein.
In one embodiment, as shown in FIGS. 1-3, 5A and 5B , the transport mechanism 204 is a conveyor belt 206 operable to transport (e.g., convey) the containers 500 to an entrance location or port 110 and subsequently through the entrance location or port 110 and into the detection system 100 . However, other means or mechanisms for transporting the specimen containers 500 from the loading station or area 202 to the entrance location or port 110 are envisioned, and may include, but are not limited to, feed screws, timing belts having grooves or molded plates, and the like. In other embodiments, the process of automated loading of a specimen container 500 into the detection system 100 may further comprise transferring the container to a holding structure or rack using a transfer mechanism 650 or moving the container to one or more work-flow stations using a container locator device (see, e.g., FIG. 24, 400A ), as described below.
As shown in FIGS. 1-3, 5A and 5B , the loading station or area 202 and transport mechanism 204 comprise a conveyor belt 206 . In accordance with this embodiment, the user or technician can place one or more specimen containers 500 at a specific location or area (i.e., the loading station or area 202 ) of the conveyor belt 206 for automated loading of the containers 500 into the detection system 100 . The conveyor belt 206 may run continuously, or may be activated by the physical presence of the container 500 at the loading station or area 202 . For example, a system controller can be used to operate the conveyor belt 206 (i.e., turn it on or off) based on a signal (e.g., a light sensor) indicating the presence, or absence, of one or more specimen containers at the loading station 202 . Similarly, one or more sensors can be used at the entrance location or port 110 to indicate if a container is improperly loaded and/or has fallen over and may cause jamming The conveyor belt 206 operates to move or transport the containers 500 from the loading station or area 202 (e.g., the left portion of the conveyor belt 206 , as shown in FIG. 1 ) to the entrance location or port 110 , thereby accumulating one or more containers 500 at the entrance location or port 110 to be loaded into the detection system 100 . Typically, as shown in FIGS. 1-3 and 5A-5B , the loading station or area 202 , transport mechanism 204 or conveyor belt 206 , and entrance location or port 110 are located outside, or on the housing 102 of the detection system 100 . In one embodiment, the automated loading mechanism 200 is located on a shelf 180 located on top of the lower section 170 and adjacent to the upper section 160 of the system 100 . Also, as shown, the transport mechanism or conveyor belt 206 typically operates in a horizontal plane, so as to maintain the specimen containers 500 in a vertical or up-right orientation (i.e., such that the top portion 506 of the container 500 is up) for loading into the detection system 100 (see, e.g., FIGS. 1-3 and 5A-5B ). As shown in FIGS. 1-3 , the transport mechanism or conveyor belt 206 moves, for example, from left-to-right, or from the loading station or area 202 towards the entrance location or port 110 , to transport one or more free standing containers 500 (see, e.g., FIG. 2 , arrow 208 ).
In one embodiment, as shown, for example in FIGS. 1-3 and 10-11 , the automated loading mechanism 200 will further comprise one or more guide rails 210 located juxtaposed to one or both sides of the transport mechanism or conveyor belt 206 . The one or more guide rails 210 function to guide or direct the specimen containers 500 to the entrance location or port 110 during operation of the transport mechanism or conveyor belt 206 . In one embodiment, the guide rails operate to funnel or guide the specimen containers into a single file line at the back of the automated loading mechanism 200 , where they await their turn to be loaded, one container at a time, into the detection system 100 . In another design aspect, as shown for example in FIG. 22 , the detection system 100 may further comprise a locator device cover 460 that covers a locator device (described elsewhere herein) and encloses an interior locator device chamber (not shown) therein. The locator device cover 460 may comprise one or more container guide rails 462 for guiding a specimen container 500 , as it is transported from the automated loading mechanism 200 to the entrance location or port 110 , and subsequently into the interior chamber, thereby automatically loading the specimen contain into the system. In accordance with this embodiment, the interior locator device chamber (not shown) is considered to be a part of the interior chamber, which is described elsewhere herein.
In still another embodiment, the automated loading mechanism 200 may further comprise a means or device for reading or otherwise identifying the specimen containers 500 as the containers enter the detection system 100 . For example, the containers 500 may include a bar code label 508 which can be read for container identification and tracking within the system. In accordance with this embodiment, the detection system 100 will include one or more bar code readers (see, e.g., 410 in FIGS. 14-15 ) at one or more locations within the system. For example, the detection system 100 may include a bar code reader at the entrance location or port 110 to read, identify and log the individual containers 500 into the detection system controller as they enter the system. In another embodiment, the entrance location or port 110 may also include a means or device (e.g., a container rotator or rotating turntable, as described elsewhere herein) for rotating the container within the entrance location or port 110 to enable reading of the bar code label 508 . In another possible embodiment, the transfer mechanism (see, e.g., FIG. 5B, 650 ) may rotate the container 500 to enable reading of the bar code label 508 . Once the bar code has been read, the transfer mechanism will typically transfer the container 500 from the entrance location or port 110 to one of a plurality of receiving structures or wells 602 in one of a plurality of holding structures or racks 600 .
In yet another embodiment, if the bar code 508 cannot be properly read, (e.g., the label is misread or a reading error occurs) the detection system controller (not shown) can direct the container 500 to a misread/error location or port 120 for user access to the unreadable or misread container 500 . The user can re-load the container using the automated loading mechanism 200 and/or at the user's discretion, may optionally manually load the container 500 and hand enter container 500 information into the system controller (e.g., using the user interface 150 ). In another embodiment, the detection system 100 may contain a high priority (or STAT) loading location (not shown) for the loading of high priority containers and/or for manual loading of containers where the label has been misread or a reading error has occurred.
Another design configuration of the automated loading mechanism is shown in FIG. 10 . As shown in FIG. 10 , the automated loading mechanism 200 comprises a loading station or area 202 , a first conveyor belt 206 , and an entrance location or port 110 . The conveyor belt 206 operates to transport the specimen containers 500 from the left edge of the system 100 (i.e., the location of the loading station 202 ) to the entrance location or port 110 . In this example, the movement is from left-to-right and is represented by arrow 220 in FIG. 10 . The automated loading mechanism 200 may further comprise a guide rail 210 and a second conveyor belt 212 , which operates around a set of gears or wheels 214 , 216 . In accordance with this embodiment, the second conveyor belt 212 is orientated and operable in a vertical plane above the first horizontal conveyor belt 206 , and can operate in a clockwise or counter-clockwise manner (i.e., to move the belt from left-to-right or from right-to-left). The clockwise or counter-clockwise operation of the second vertically orientated conveyor belt 212 can provide the specimen container 500 with a counter-clockwise or clockwise rotation, respectively, about a vertical axis of the container. Applicants have found that providing a specimen container 500 with clockwise or counter-clockwise rotation can prevent and/or reduce jamming or clogging of the automated loading mechanism 200 as a plurality of specimen containers 500 accumulate at the entrance location or port 110 . Once the containers 500 have arrived at the entrance location or port 110 they can be moved into the detection system 100 .
In still another embodiment, the automated loading mechanism 200 may also contain a backer board (not shown) located in a horizontal plane underneath the first conveyor belt 206 . As one of skill in the art would appreciate, the conveyor belt 206 may have some give, flexibility, or may otherwise be considered “springy”. This springy nature of the conveyor belt 206 may lead to instability of the specimen container 500 as the container is transported across the conveyor belt 206 from the loading station or area 202 to the first port or entrance location 110 and may result in specimen containers 500 tipping or falling over. Applicants have found that by including a rigid or semi-rigid backer board underneath the conveyor belt 206 , this problem can be reduce and/or eliminate altogether, thereby, reducing and/or preventing jamming or clogging of the loading mechanism 200 (e.g., with containers 500 that have fallen over). In general, any known backer board material may be used. For example, the backer board can be a rigid or semi-rigid board made of plastic, wood, or metal.
Yet another configuration of the automated loading mechanism is shown in FIG. 11 . As shown in FIG. 11 , the automated loading mechanism 200 may comprise a loading station or area 202 , a conveyor belt 206 , and an entrance location or port 110 . Also as shown, the conveyor belt 206 can operate to transport the specimen containers 500 from the front edge of the system 100 (i.e., the loading station 202 ) to the entrance location or port 110 . In this example, the movement of the loading mechanism 200 is from front-to-back (i.e., from the front edge of the instrument to the loading port 110 ) and is represented by arrow 240 in FIG. 11 . As shown, the automated loading mechanism 200 may further comprise one or more guide rails 210 to guide the one or more specimen containers 500 to the entrance location or port 110 , as they are transported by the conveyor belt 206 .
Optionally, as shown in FIG. 11 , the automated loading mechanism 200 , in accordance with this embodiment, may include a second transport mechanism 230 . In one embodiment, the second transport mechanism 230 may comprise a second conveyor belt 232 located in, and operable in, a vertical plan above the first conveyor belt 206 . As shown, the second transport mechanism 230 may further comprise a plurality of paddles or plates 236 attached to the second conveyor belt 232 . In accordance with this embodiment, the first conveyor belt 206 operates to move or transport one or more specimen containers 500 from the loading station or area 202 to the second transport mechanism 230 , where the containers 500 are individually moved or transported into a well or space 234 between the paddles or plates 236 . The second conveyor belt 232 operates around a set of gears or drive wheels (not shown), and runs or moves, for example, from left-to-right across the back edge of the automated loading mechanism 200 , thereby transporting the containers 500 from left-to-right along the back of the loading mechanism 200 and to the entrance location or port 110 (see, e.g., arrow 250 ). Once the containers 500 have arrived at the entrance location or port 110 they can be moved into the detection system 100 .
In yet another embodiment, the automated loading mechanism 200 can be enclosed or encased in a protective housing or casing 260 , as shown for example in FIG. 12 . In accordance with this embodiment, the automated loading mechanism 200 , or one or more components thereof (i.e., one or more of the loading area, transport means (e.g., conveyor belt 206 ) and/or entrance location or port (not shown)), can be housed or encased in a protective housing or casing 260 . The protective housing or casing 260 will have an opening 262 providing access to, and for loading specimen container 500 into/onto the automated loading mechanism 200 housed therein. Optionally, the protective housing or casing 260 can further include a cover means 264 that can be closed or shut to protect the automated loading mechanism 200 , and/or containers 500 , contained therein. The cover can be a closable lid 266 , as shown, or other structure or means for closing the housing or casing 260 . For example, in another embodiment, the cover 264 can be a lightweight curtain (not shown) that can be pulled shut over the opening 262 . The protective housing or casing 260 may also provide a priority container loading port 270 for the loading or high priority containers (i.e., STAT container) and/or misread containers. In one embodiment, a container 500 can be manually loaded into the priority port 270 .
Another embodiment of an automated loading mechanism is shown in FIGS. 13-15 . Like the previously described automated loading mechanism, the automated loading mechanism 300 shown in FIGS. 13-15 , comprises a container loading station or area 302 , a transport mechanism 304 and a container entrance location 306 , for the fully automated loading of one or more specimen containers 500 into the detection system 100 .
The container loading area 302 is in an easily accessible location on the detection system 100 to allow a user to easily place one or more specimen containers 500 therein, as shown for example in FIG. 17 . In accordance with this embodiment, the specimen containers 500 are loaded in a horizontal orientation, such that they are lying on their side, as shown for example in FIG. 13 . Once at the container loading area 302 , the specimen containers 500 can be transported by a transport mechanism 304 from the container loading area 302 to an entrance location 306 , from where the containers 500 will enter the detection system 100 , as described in more detail herein. Surprisingly, regardless of the specimen container 500 orientation in the loading area 302 (i.e., regardless of whether the top portion 506 of the container 500 is facing the detection system 100 or facing away from the detection system 100 (as shown, e.g., in FIG. 14 )), the automated loading mechanism 300 of this embodiment is capable of loading the specimen containers 500 into the detection system 100 .
In one embodiment, the container loading station or area 302 comprises a loading reservoir 303 that is capable of holding one or more specimen containers 500 , as shown for example in FIG. 13 . The loading reservoir 303 can be designed to hold from 1 to 100 specimen containers, from 1 to 80 specimen containers, or from 1 to 50 specimen containers. In other design concepts, the loading reservoir may hold 100 or more specimen containers 500 . The automated loading mechanism 300 of this embodiment may further comprise a lid or cover (not shown), which the user or technician can optionally close to cover the loading reservoir 303 and loading area 302 . Various designs are possible and contemplated for the lid or cover.
As show in FIGS. 13-14 , the loading reservoir 303 contains a transport mechanism 304 , for example, a sloped ramp that slopes downwards towards an entrance location 306 so as to transport the specimen containers 500 from the loading area 302 to the entrance location 306 . In accordance with this embodiment, the sloped ramp will allow the specimen containers to roll or slide down the ramp to the entrance location 306 . Although, a sloped ramp is exemplified in the figures other designs are possible and contemplated for the transport means or mechanism 304 for transporting the specimen containers to the entrance location 306 . For example, in one alternative design concept the transport mechanism 304 may comprise a conveyor belt (not shown). In accordance with this design concept the conveyor belt can be designed to hold one or more specimen containers and may optionally be designed such that the conveyor belt slopes downward towards the entrance location 306 .
Once at the entrance location 306 , a drum or drum-like loading device 308 will be used for loading the specimen containers 500 into the detection system 100 . As shown, the drum-like loading device 308 has one or more horizontally orientated slots 310 for holding one or more specimen containers therein. Each individual slot 310 is capable of holding a single specimen container 500 . In one embodiment, the drum-like loading device 308 has a plurality of slots, for example, from 1 to 10 slots, from 1 to 8 slots, from 1 to 6 slots, from 1 to 5 slots, from 1 to 4 slots, or from 1 to 3 slots for holding specimen containers 500 therein. In another embodiment, the drum-like loading device 308 can be designed to have a single slot capable of holding a single specimen container 500 therein.
The drum-like loading device 308 is capable of rotating (either in a clock-wise direction, or counter-clock wise direction) about a horizontal axis, and is capable of picking-up and loading individual specimen container 500 into the detection system 100 . In operation, the rotation of the drum or drum-like loading device 308 picks up a horizontally orientated specimen container 500 in one of a plurality of horizontally orientated slots 310 , and moves the container 500 , by rotation of the drum or drum-like loading device to a tumbler device 330 (see, e.g., FIG. 16 ). Any known means in the art can be used for rotation of the drum or drum-like loading device 308 . For example, the system may employ the use of a motor (not shown) and drive belt 316 for rotation of the drum-like loading device 308 .
In another embodiment, as shown in FIG. 13 , the automated loading mechanism 300 of this embodiment may further comprise a single container loading port 312 . In operation, a user or technician can place a single specimen container into the single container loading port 312 for quick, or immediate loading, for example of a STAT specimen container. Once placed in the single container loading port 312 , the container will drop or fall via gravity onto a second transport mechanism 314 , for example, a sloped ramp that slopes downward toward the drum-like loading device 308 for quick or immediate automated loading of the specimen container into the detection system 100 .
As shown in FIGS. 13-16 , the drum or drum-like loading device 308 rotates in a vertical plane (i.e., around or about a horizontal axis) to move the specimen container 500 from the entrance location 306 to a tumbler device 330 . The tumbler device comprises an open slot at the top of a vertically orientated chute 332 . Once moved to the tumbler device 330 , the specimen containers are up-righted (i.e., the specimen containers are re-positioned from a horizontal container orientation to an up-right vertical container orientation) by a cam mechanism and vertically orientated chute 332 . In operation, the cam mechanism (not shown) is capable of sensing the top and/or bottom of the specimen container, and pushing the specimen container 500 in a horizontal direction from the base of the specimen container, thereby allowing the base to drop or fall through the opening of a vertically orientated chute 332 . Accordingly, the tumbler device 330 operates to allow the container 500 to drop (via gravity) bottom first through the vertical chute 332 and into a first locator well of a container locator device 400 (described elsewhere herein), thereby re-orientating the container 500 in a vertical, up-right orientation.
As shown for example in FIG. 16 , the tumbler device 330 has two tapered ledges 334 , one on each side of the drum, each being narrow at a front edge and thicker at a back edge. The ledges 334 are aligned so that the cap portion 502 of the container 500 will be caught or held by the ledge (i.e., the cap will move over the top side of the ledge such that the cap will rest on the top of ledge 334 ) as the drum rotates. The ledge 334 only holds the cap portion 502 of the container 500 in place briefly, as the bottom of the container falls through the vertical chute 332 . Furthermore, the bottom or base 506 of the container will not be caught or held by the ledge. Instead, the tapered ledge 334 will act to push or slide the bottom or base 506 of the container 500 in a horizontal direction, from the bottom 506 of the container 500 towards the top or cap portion 502 of the container (see FIG. 4 ), as the drum or drum-like loading device 308 rotates. This action helps to ensure that the cap end 502 of the container is held by the top edge of the ledge 334 , thereby allowing the bottom 506 of the container 500 to fall freely through the vertical chute 332 and into the container locator device 400 . By having a ledge 334 on each side of the drum or drum-like loading device 308 , container 500 orientation in the rotating drum in not essential. The container 500 will be up-right by the tumbler device 330 regardless of whether the cap end 502 of the container is on the right or left side (see, e.g., FIG. 16 ) of the drum-like loading device 308 , as the corresponding ledges 334 will function to hold the cap or top 502 of the container as the bottom 506 falls through the vertical chute 332 . In another embodiment, the vertical cute 332 may further comprise a narrower section 333 that helps direct the falling container 500 into the container locating device 400 . In operation, as the drum or drum-like loading device 308 rotates over the open slot at the top of the vertically orientated chute 332 , the cap or top portion 502 of the container 500 is held at the outer edge of the drum by one or more ledges 334 (see, e.g., FIG. 16 ). The ledges 334 hold the cap or top portion 502 of the container 500 in place while allowing the bottom 506 of the container to swing or fall freely out of the drum or drum-like loading device 308 and into the vertically orientated chute 332 , thereby up-righting or vertically orientating the container 500 as it drops or falls via gravity through the vertically orientated chute 332 bottom first, as previously described.
Container Management Means or Locator Device
As shown, for example in FIGS. 13-15, 18, and 25A-25C the detection system 100 may further comprise a container management device or locator device 400 . The container management device or locator device 400 can be used to manage, move or otherwise locate a container 500 , once inside the housing 102 of the detection system 100 , among various work-flow stations 404 . In one embodiment, the container management device or locator device 400 can be used in combination with the automated loading mechanism 300 shown in FIGS. 13-15 , as shown. In another embodiment, the container management device or locator device 400 can be used in combination with the automated loading mechanism 200 shown, for example, in FIG. 18 . The container management device or locator device 400 in FIGS. 13-15 and 18 is shown schematically and the parts are not to scale.
The container management device or locator device 400 comprises a rotatable wheel-like device or rotatable disk that contains one or more locator wells 402 , for example 1 to 10 locator wells, 1 to 8 locator wells, 1 to 5 locator wells, 1 to 4 locator wells, or 1 to 3 locator wells 402 . In one embodiment, the locator device comprises opposable parallel plates or discs (see, e.g., FIGS. 25A-25C ). Each individual locator well 402 is capable of holding a single specimen container 500 . In operation, the locator device 400 rotates (either clock-wise or counter clock-wise) in a horizontal plane (and around or about a vertical axis) to move an individual container 500 to or among various work-flow stations 404 (i.e., from station-to-station). In one embodiment, the work-flow station 404 is operable to obtain one or more measurements or readings of the specimen container, thereby providing information about the container, such as, container lot number, container expiration date, patient information, sample type, fill level, etc. In another embodiment, the one or more work-flow stations 404 may comprise one or more container management stations, such as, a container pick-up station or a container transfer station. For example, the locator device 400 is capable of moving an individual specimen container 500 to and/or among one or more work-flow stations 404 , such as: (1) a bar code reading station; (2) a container scanning stations; (3) a container imaging station; (4) a container weighing station; (4) container pick-up station; and/or (5) a container transfer station. In another embodiment, one or more of these measurements and/or readings can occur at the same station. For example, container weight, scanning, imaging and/or pick-up may occur at a single station location. In yet another embodiment, the detection system may contain a separate pick-up station. A container can be picked-up by a transfer mechanism (as described herein) at the pick-up location, and transferred to other locations (e.g., to a holding structure and/or agitation assembly) within the detection system 100 . In still another embodiment, the detection system 100 may contain a transfer station for the transfer of a specimen container 500 to another instrument, e.g., a second automated detection instrument. In accordance with this embodiment, the transfer station may communicate with a system transfer device 440 . For example, as shown, the system transfer device 440 may be a conveyor belt that allows the specimen container to be transferred to another location within the detection system 100 , or in another embodiment, to another instrument (e.g., a second detection system (e.g., as shown in FIG. 24 )). As shown in FIG. 14-15 , the locator device 400 comprises: (1) an entrance station 412 ; (2) a bar code reading and/or scanning station 414 ; (3) a container weighing station 416 ; (4) a container pick-up station 418 ; and (5) a system transfer station 420 for transfer of the container to another instrument. The locator device may further comprise a rotatable turntable device 406 positioned at any work-flow station. Typically such a rotatable turntable device can be used for rotating a container to facilitate bar code reading and/or container scanning, and/or a scale or weighing device 408 , for weighing a container.
As previously described, in operation, the container management device or locator device 400 , operates to move or otherwise locate a given specimen container 500 to a given work-flow station 404 . In one embodiment, these work-flow stations 404 are included within the housing 102 of the detection system 100 . For example, as shown in FIGS. 13-15 and 18 , an automated loading mechanism can deposit or place a specimen container 500 into a locator well 402 , as described elsewhere herein. The container management means or locating device 400 can then rotate to move or locate the specimen container among various work-flow stations within the system, such as for example, a bar code reading station, a container scanning stations, a container imaging station, a container weighing station, container pick-up station, and/or a container transfer station.
In one embodiment, the container locator device 400 moves the specimen container to the container pick-up station 418 . In one embodiment, the container pick-up station is between the imaging work-station and the container transfer station for transfer to a downstream instrument. The container pick-up station 418 is a location within the system where the automated transfer mechanism (e.g., the robot for loading the specimen container into the holding structure). In some embodiments, the container pick-up station includes an opening in the side of the container locator device for removing the specimen container from the container locator device and inserting it into a well of the holding structure, if the system controller determines that the specimen container should be loaded into the automated detection apparatus. If the system controller determines that the specimen container should be moved downstream, the container locator device can rotate and move the specimen container from the container pick-up station to the container transfer station.
In some embodiments, the container transfer station is part of a system for transferring specimen containers from a first automated microbial detection apparatus to a second automated microbial detection apparatus. In one embodiment, the system includes a first automated microbial detection apparatus comprising: a housing enclosing an interior chamber; a specimen container locator device comprising one or more locator wells for receiving said specimen container and for moving said specimen container to one or more work stations within said interior chamber, wherein one of the work stations is a container transfer station; a transfer arm proximate to the container transfer station; a first sensor configured to detect a specimen container at the container transfer station; and a second sensor configured to detect when the transfer arm has transferred the specimen container to the second automated microbial detection apparatus. In this embodiment, the second automated microbial detection apparatus includes an automated loading mechanism; a gate between the container transfer station of the first automated microbial detection apparatus and the automated loading mechanism of the second automated microbial detection apparatus; a third sensor configured to determine that the gate is away from a home position.
The system for transferring specimen containers from a first automated microbial detection apparatus to a second automated microbial detection apparatus includes many of the structures already disclosed herein, such as the housing, the specimen container locator device, and the automated loading mechanism. The system may also contain new elements such as a container transfer station, various sensors for facilitating the transfer, and a transfer arm for transferring the specimen container from the first detection instrument to the second detection instrument.
As used herein, the container transfer station is a defined station in the automated microbial detection apparatus where a specimen container may be transferred to a second (or third, etc.) downstream automated microbial detection apparatus. The structure of the container transfer station is configured to receive a specimen container that has been loaded into the automated microbial detection apparatus. Upon loading, the specimen container enters the specimen container locator device. In some embodiments, the system controller determines that the specimen container should be transferred to a downstream instrument for testing. This may be because the present detection apparatus is full, malfunctioning, or for other load-balancing reasons. In one embodiment, the specimen container locator device rotates to transport the specimen container, which is positioned in a locator well of the specimen container locator device, to the container transfer station.
Turning to FIGS. 25D and 25E , perspective views of an embodiment of the container transfer station are provided. In this embodiment, the transfer arm 454 receives the specimen container 500 from the locator well 402 as the specimen container locator device 400 rotates in a clockwise direction. In one embodiment, the transfer arm 454 is configured to automatically open to receive the specimen container as the specimen container locator device 400 rotates. In further embodiments, the transfer arm 454 is positioned on a pivoting structure so that if the specimen container locator device rotates counter-clockwise with specimen containers in the locator wells, the transfer arm moves out of the path traveled by the specimen container. For example, in some embodiments, the specimen container is removed from the incubation chamber and rescanned at the bar code scanning station. In this embodiment, the specimen container would move from the pick-up location to the scanning location.
In one embodiment, the transfer arm 454 includes a gripping mechanism 456 associated with the transfer arm 454 and configured to grip the specimen container. For example, opposing paddles configured to grip the specimen container may form part of the transfer arm 454 . In some embodiments, the opposing paddles are curved to surround at least a portion of the circumference of the specimen container when gripping the specimen container. The opposing paddles may also have one or more ridges for gripping the specimen container. In some embodiments, one of the paddles is fixed and the second paddle is movable from an open position to receive the specimen container to a closed position for holding the specimen container.
In some embodiments, the transfer arm 454 grips the specimen container 500 and then lifts the specimen container a predetermined distance from the surface of the container transfer station. In this embodiment, the specimen container is lifted so that it can pass over potential gaps when it is transferred to the downstream detection instrument. When two detection units are arranged side-by-side, the units may be placed at a height so that the exit from the first unit is substantially the same height as the automated loading mechanism 200 (e.g., conveyor belt) of the downstream unit. Nevertheless, a gap may be present as well as a small height difference that has the potential to tip over the specimen container were it to be slid from the first unit to the downstream unit. For this reason, the system may lift the specimen container prior to transferring it to the downstream unit.
In some embodiments, the transfer arm includes a spring configured to lift the transfer arm and specimen container. In further embodiments, a motor may be associated with the transfer arm that alone or with assistance of the spring lifts the transfer arm and specimen container. In some embodiments, the motor also assists in causes the opposing paddles to grip the specimen container and/or causing the transfer arm to move between a home position, a pick-up position, and a release position.
The home position for the transfer arm is a neutral position where the arm is positioned to not interfere with rotation of the specimen container locator device and is also not extended towards the downstream instrument for releasing the specimen container onto the automated loading mechanism of the downstream instrument. The pick-up position is a position of the transfer arm when it is configured to receive the specimen container from the locator well of the specimen container locator device. The release position is the extended position of the transfer arm when it releases the specimen container onto the automated loading mechanism of the downstream instrument.
In some embodiments, the system includes a hard stop in the container transfer station configured to position the transfer arm at a pick-up position for the specimen container. In one embodiment, the gripping mechanism introduces a range of motion that may result in error when the specimen container is received from the locator well. In this embodiment, a hard stop may be used in the system to ensure that one of the opposing paddles is appropriately position to receive the specimen container. In some embodiments, the hard stop is positioned so that one of the opposing paddles is resting against it when the specimen container is received. In this manner, the range of motion is limited in one direction and the position of the gripping mechanism is consistently positioned to receive the specimen container without interfering with its placement. The system may also include a hard stop configured to halt movement of the transfer arm when the transfer arm is extended to the release position.
In some embodiments, the system also includes a first sensor (not shown) configured to detect a specimen container at the container transfer station. The sensor may be operatively connected to the system controller. In some embodiments, the sensor is an optical sensor configured to detect when an object, such as the specimen container, has entered a specific region. In one embodiment, the first sensor is a convergent reflective micro photoelectric sensor by SunX™ (e.g., model number PM2-LH10-C1).
In some embodiments, the system includes a second sensor 458 configured to detect when the transfer arm has transferred the specimen container to the second automated microbial detection apparatus. For example, a Sick™ photoelectric proximity sensor may be used (e.g., model number WTB4-3N1164). In one embodiment, the second sensor is positioned to detect when the specimen container is in the transfer arm in the release position. In other words, the second sensor detects when the specimen container has been transferred to a position over the automated loading mechanism of the downstream instrument. In one embodiment, the second sensor detects the cap of the specimen container.
In one embodiment, the system includes an alarm configured to alert a user when the second sensor does not detect the specimen container after the first sensor detects the specimen container. For example, the first sensor may detect that a specimen container entered the container transfer station but then, for some reason, this specimen container falls over or becomes jammed In this situation, the second sensor would not detect the specimen container. In one embodiment, the second sensor has a time limit to detect the specimen container before the alarm is triggered. The alarm may be a written notification, a visual alarm such as a light, and/or an audible alarm such as a tone.
In a further embodiment, the system includes a gate 464 between the container transfer station of the first automated microbial detection apparatus and the automated loading mechanism of the second automated microbial detection apparatus. As shown in FIG. 25D , the gate 464 is positioned at the entrance to the automated loading mechanism of the downstream instrument. In some embodiments, the gate 464 is mounted on a hinge and swings open in one direction as the transfer arm transfers the specimen container from the container transfer station to the downstream instrument. In one embodiment, the gate 464 is sized to swing out of the way when the specimen container is transferred to the downstream instrument but then retract back into place to prevent backwards movement of the specimen container.
In further embodiments, the system includes a third sensor (not shown) configured to determine that the gate is away from a home position. For example, a Photologic® Slotted Optical Switch “Wide Gap Series sensor by OPTEK Technology may be used (e.g., model number CPB910W55Z). In this embodiment, a sensor is configured to determine when the gate has started to move from the home position as shown in FIG. 25D to an open position as shown in FIG. 25E . In some embodiments, the sensor is positioned to detect the initiation of movement so that the automated loading mechanism can be activated. It has been found that initiating the automated loading mechanism immediately before the specimen container arrives assists in loading the specimen container onto the automated loading mechanism. In some embodiments, the automated loading mechanism starts within about 500 msec of the third sensor detecting that the gate has moved away from the home position. The variation in the position of the released specimen container is reduced when the automated loading mechanism is running as the specimen container is released. When the automated loading mechanism is not running, the transfer arm may push the specimen container forward and cause variation in its position on the automated loading mechanism. When the automated loading mechanism is running, however, the specimen container moves out of the gripping mechanism of the transfer arm due to the movement of the automated loading mechanism. This also reduces the likelihood that the specimen container will tip over or fall when released onto the automated loading mechanism. The position of the third sensor can be within the wall of the downstream instrument or opposite the automated loading mechanism from the attachment point of the gate to the downstream instrument. In an exemplary embodiment, the third sensor is operatively connected to the system controller.
In some embodiment, the system also includes a fourth sensor (not shown) positioned proximate to an entrance location of the second automated microbial detection apparatus. For example, a Sick™ miniature photoelectric sensor may be used (e.g., model number WLG4S-3E1134). In this embodiment, the entrance location is the entrance to the specimen container locator device of the downstream instrument. In some embodiments, the fourth sensor is configured to detect a specimen container on the automated loading mechanism of the downstream instrument. The fourth sensor is used to determine when the automated loading mechanism of the downstream instrument may halt. In some embodiments, the fourth sensor monitors for specimen containers on the automated loading mechanism after the automated loading mechanism is triggered. When the fourth sensor does not detect a specimen container for a set period of time, e.g., about ten seconds, the system halts the automated loading mechanism. It should be understood that the length of time may vary based on the speed and/or length of the automated loading mechanism.
In some embodiments, the system also includes a conveyor cover for covering the automated loading mechanism. In one embodiment, the system will not transfer a specimen container to a downstream instrument when the system determines that the conveyor cover is removed on the downstream instrument. In this embodiment, the system may still be able to load bottles on the upstream and downstream instruments by individually loading specimen containers onto each instrument's respective automated loading mechanism.
In further embodiments, the system includes a fifth sensor (not shown) positioned to determine when the transfer arm is at a home position. For example, a Photologic® Slotted Optical Switch “Wide Gap Series sensor by OPTEK Technology may be used (e.g., model number CPB910W55Z). In one embodiment, the fifth sensor is positioned to detect when the transfer arm is at the home position. The fifth sensor can be used to determine whether the transfer arm would interfere with counter-clockwise movement of the specimen container locator device. Similarly, the fifth sensor can be used to determine whether the transfer arm is being interfered with by the specimen container, e.g., if a jam occurs when the transfer arm is transferring the specimen container to the downstream instrument.
It should be understood that while optical sensors are disclosed herein, other types of sensor may make up one or more of the first through fifth sensors. For example, inductive, capacitive, and/or magnetic sensors may be used to detect the presence of objects, such as specimen containers, or the position of objects, such as gates and transfer arms.
Transfer Means or Mechanism
As shown, for example in FIGS. 5-9B and 17-21 , the automated detection system 100 may further comprise an automated transfer means or mechanism operable for the transfer of a specimen container 500 , and/or for container management, within the system. As already described, the entrance location or port 110 receives containers from, for example, a conveyor system 206 shown best in FIGS. 1-3 . As the containers accumulate in the entrance location or port 110 , the containers are moved within the detection system 100 whereby a transfer mechanism (e.g., a robotic transfer arm with a container gripping means) can pick-up, or otherwise receive, an individual specimen container 500 and transfer and place that container into a holding structure or rack 600 within the detection system 100 , as described in more detail herein. The transfer mechanism may use a vision system (e.g., camera), pre-programmed dimensional coordinates and/or precision motion controlling to transfer a specimen container to, and load the specimen container into, the holding structure or rack 600 .
As shown in FIGS. 1-3 and 13-15 , specimen containers 500 are loaded into, and/or transported within, the detection system 100 using an automated loading mechanism 200 ( FIG. 1-3 ) or 300 ( FIGS. 13-15 ). As shown, the containers 500 are typically loaded into the detection system 100 in a vertical orientation (i.e., such that the top or cap portion 502 of the container 500 is up-right). In accordance with one embodiment, the containers 500 are placed or held in a plurality of holding structures or racks 600 , and optionally agitated to enhance microorganism growth therein. As shown for example in FIGS. SA and 5 B, the receiving structures or wells 602 of the holding structures or racks 600 can be orientated in a horizontal axis. Accordingly, in accordance with this embodiment, an automated transfer mechanism (see, e.g., FIG. 5B, 650 ) must re-orientate the container 500 , from a vertical orientation to a horizontal orientation, during the transfer of the container 500 from the automated loading mechanism 200 , 300 to the receiving structures or wells 602 .
In operation, the automated transfer mechanism (e.g., FIG. 5B, 650 or FIG. 20, 700 ) can operate to transfer or otherwise move, or relocate, a specimen container 500 within the interior chamber 620 of the detection system 100 . For example, in one embodiment, the transfer mechanism can transfer a specimen container 500 from an entrance location or port 110 to one of a plurality of holding structures or racks 600 . In another embodiment, the transfer mechanism can pick-up a specimen container 500 from a well 402 of the container locator device 400 and transfer the container to a holding structure or well 602 of the holding structure or rack 600 . The transfer mechanism can operate to place the container 500 in one of a plurality of container receiving structures or wells 602 that are located in one of a plurality of holding structures or racks 600 . In another embodiment, the transfer mechanism can operate to remove or unload “positive” and “negative” containers from the holding structures or racks 600 . This automated unloading mechanism can operate to ensure that once a “positive” or “negative” reading has been made for each specimen container 500 , the container 500 is removed from the container receiving structures or well 602 , making room for another container to be loaded into the detection system 100 , thereby increasing system through-put.
In one embodiment, the transfer mechanism can be a robotic transfer arm. In general, any type of robotic transfer arm can be used. For example, the robotic transfer arm can be a multi-axis robotic arm (for example, a 2-, 3-, 4-, 5-, or 6-axis robotic arm). The robotic transfer arm can operate to pick-up and transfer a specimen container 500 (e.g., a blood culture bottle) from an entrance location or port 110 to one of a plurality of container receiving structures or wells 602 located in one of a plurality of holding structures or racks 600 (optionally having an agitation assembly). Furthermore, to facilitate the necessary movements of the transfer mechanism or robotic transfer arm, the interior chamber 620 of the detection system 100 , may includes one or more supports for the robotic transfer arm. For example, one or more vertical supports and/or one or more horizontal supports may be provided. The transfer mechanism or robotic transfer arm will slide up and down and across the supports as necessary to access any of the receiving structures or wells 602 of the holding structures or racks 600 . As previously described, the robotic transfer arm can operate to change the orientation of a specimen container from a vertical orientation (i.e., up-right orientation such that the top 502 of the container 500 is up) to a horizontal orientation (i.e., such that the container 500 is laying on it's side), for example, to facilitate in container transfer from a loading station or location, and placement within a holding structure and/or agitation assembly.
In one embodiment, the robotic transfer arm is a 2-, or 3-axis robotic arm and will be capable of transferring the container 500 in one or more horizontal axes (for example, the x- and/or z-axes) and optionally a vertical axis (y-axis) to a specific location, such as the container receiving structures or wells 602 described herein. In accordance with this embodiment, a 2-axis robotic arm will allow movement in 2-axes (for example, the x-, and z-axes), whereas a 3-axis robotic arm will allow movement in 3-axes (for example, the x-, y-, and z-axes).
In another embodiment, the 2-, or 3-axis, robotic arm may further employ one or more rotational movements, capable of transferring or moving the specimen container 500 rotationally about one or more axes. This rotational movement may allow the robotic transfer arm to transfer a specimen container 500 from a vertical loading orientation to a horizontal orientation. For example, the robotic transfer arm may employ a rotational movement to move the specimen container rotationally about or around a horizontal axis. This type of robotic transfer arm would be defined as a 3-, or 4- axis robotic arm. For example, a robotic arm that allows movement in one horizontal axis (the x-axis), one vertical axis (e.g., the y-axis) and one rotational axis would be considered a 3-axis robotic arm. Whereas, a robotic arm that allows movement in two horizontal axes (e.g., the x-, and z-, axes), a vertical axis (the y-axis) and one rotational axis would be considered a 4-axis robotic arm. Similarly, a robotic arm that allows movement in a single horizontal axis (e.g., the x-axis), a vertical axis (the y-axis) and two rotational axes would also be considered a 4-axis robotic arm. In yet another embodiment, the robotic transfer arm 700 can be a 4-, 5-, or 6-axis robotic arm, thereby allowing movement in the x-, y-, and z-axes, as well as rotational movement about, or around, one-axis (i.e., a 5-axis robot), two axes (i.e., a 5-axis robotic arm), or all three horizontal (x-, and z-axes) and vertical axes (y-axes) (i.e., a 6-axis robotic arm).
In yet another embodiment, the robotic transfer arm may include one or more devices for obtaining measurements, scans and/or readings of a specimen container 500 . For example, the robotic transfer arm may include one or more video cameras, sensors, scanners, and/or bar code readers. In accordance with this embodiment, the video camera, sensor, scanner and/or bar code reader may aid in container location, reading of container labels (e.g., bar codes), container scanning, remote field servicing of the system, and/or detecting for any possible container leaks within the system. In yet another design possibility, the robotic transfer arm may include a UV light source to aid in automated decontamination, if necessary.
One design possibility of the transfer mechanism is shown in FIGS. 6-8C . As shown in FIG. 6 , the transfer mechanism comprises a robotic transfer arm 650 , which comprises an upper horizontal support rail 652 A, a lower horizontal support rail 652 B, a single vertical support rail 654 and a robotic head 656 that will includes a gripping mechanism (not shown) for picking-up, gripping or otherwise holding a specimen container 500 . The transfer mechanism shown in FIGS. 6-8C is shown schematically and the parts not to scale, for example, the horizontal supports 652 A, 652 B, vertical support and robotic head 656 shown are not to scale. As one of skill in the art would readily appreciate, the horizontal supports 652 A, 652 B, and vertical support can be increased or decreased in length as needed. As shown, the robotic head 656 is supported by, coupled to, and/or attached to the vertical support rail 654 , which in turn is supported by the horizontal support rails 652 A and 652 B. Also as shown in FIG. 6 , the transfer mechanism may comprise one or more mounting supports 696 that can be used to mount the transfer mechanism in the detection system.
In operation, the vertical support rail 654 can be moved along the horizontal support rails 652 A and 652 B, thereby moving the vertical support rail 654 and the robotic head 656 along a horizontal axis (e.g., the x-axis). In general, any known means in the art can be used to move the vertical support rail 654 along the horizontal support rails 652 A and 652 B. As shown in FIG. 6 , the upper and lower support rails 652 A and 652 B, can comprise upper and lower threaded shafts (not shown) operable to drive upper and lower horizontal slide blocks 659 A and 659 B, respectively. Also, as shown in FIG. 6 , the upper and lower shafts 652 A and 652 B can include hollow, elongate reinforcing sleeves 653 A, 653 B that extends the length of the upper and lower support rails 652 A, 652 B, and thereby surrounds the upper and lower threaded screws (see, e.g., U.S. Pat. No. 6,467,362). The sleeves 653 A, 653 B will each further comprise a slot (see, e.g., 653 C) in the sleeve 653 A, 653 B that extends the length of the upper and lower support rails 652 A, 652 B. Threaded tongues (not shown) are provided that extend through the slot (see, e.g., 653 C) and have threads engageable with the threaded shafts (not shown) which are encased in the reinforcing sleeves 653 A, 653 B. As the threaded shafts (not shown) of the upper and lower support rails 652 A, 652 B are turned by a first motor 657 , the threaded tongues (not shown) moves horizontal slide blocks 659 A, 659 B along the longitudinal length of the upper and lower support rails 652 A, 652 B, thereby moving the robotic head 656 along a horizontal axis (e.g., the x-axis) (again, see, e.g., U.S. Pat. No. 6,467,362). A first motor 657 can operate to turn the upper and lower threaded shafts (not shown) and thereby drive upper and lower horizontal slide blocks 659 A and 659 B (each having internal threads that engage the threaded shafts, respectively) in a horizontal direction along the upper and lower threaded shafts. In one design possibility, the first motor 657 can be used to turn both the upper and lower threaded shafts by including a drive belt 660 and set of pulleys 662 to turn one of the threaded shafts (e.g., the lower threaded shaft) in parallel with the first threaded shaft, as the first threaded shaft is turned by the motor 657 .
As shown in FIG. 6 , the vertical support rail 654 may further comprise a vertical threaded drive shaft (not shown) operable to drive a vertical slide block 655 and thereby move the robotic head 656 along a vertical axis (e.g., the y-axis). In operation, a second motor 658 can operate to turn a vertical threaded shaft (not shown) and thereby drive vertical slide block 655 in a vertical direction along the vertical threaded shaft. In another embodiment, as shown in FIGS. 6-7B , and as described hereinabove, the vertical threaded shaft may further comprise a hollow, elongate reinforcing sleeve 654 A that extends the length of the vertical support rail 654 , and thereby surrounds the vertical threaded shaft (not shown). The sleeve 654 A will further comprise a slot 654 B that extends the length of the vertical support rail 654 . A threaded tongue (not shown) is provided that extends through the slot (not shown) and has threads engageable with the threaded shaft (not shown). As the threaded shaft (not shown) is turned by motor 658 , the threaded tongue (not shown) moves a vertical slide block 655 , thereby moving the robotic head 656 along a vertical axis (e.g., the y-axis) (again, see, e.g., U.S. Pat. No. 6,467,362). The vertical slide block 655 may be directly attached to the robotic head 656 , or as shown in FIG. 6 , may be attached to a first rotational mechanism 664 . The vertical slide block 655 has internal threads (not shown) that engage the threaded vertical shaft and operated to drive the vertical slide block, and thus the robotic head 656 , in a vertical direction, along the threaded vertical shaft.
The transfer mechanism 650 may further comprise one or more rotational mechanisms operable to provide rotational movement about or around one or more axes. For example, as shown in FIG. 6 , the robotic head may comprise a first rotational mechanism 664 for providing rotational movement about or around the y-axis and a second rotational mechanism 665 for providing rotational movement about or around the x-axis. The first rotational mechanism 664 comprises a first rotational plate 667 that can be attached to the robotic head 656 . The first rotational mechanism 664 further comprises a first rotational motor 668 , a first pinion gear 670 and a first opposable ring gear 672 , which operate to rotate the first rotational plate 667 , and thus the robotic head 656 , about a vertical axis (e.g., about the y-axis). In one embodiment, the first pinion gear 670 and first ring gear 672 may be provided with gripping teeth (not shown) or other gripping feature (not shown). The first rotational plate 667 may be directly attached to the robotic head 656 , or as shown in FIG. 6 , may be attached to a second rotational mechanism 665 . Also as shown in FIG. 6 , the first rotational plate 667 may comprise a bent plate to facilitate attachment to the second rotational mechanism 665 . The second rotational mechanism 665 , like the first rotational mechanism 664 , comprises a second rotational plate 674 . As shown in FIG. 6 , the second rotational plate 674 is attached to the robotic head 656 . The second rotational mechanism 665 further comprises a second rotational motor 678 , a second pinion gear 680 and a second opposable ring gear 682 , which operate to rotate the second rotational plate 674 , and thus the robotic head 656 , about a horizontal axis (e.g., the x-axis). In one embodiment, the second pinion gear 680 and second ring gear 682 may be provided with gripping teeth (not shown) or other gripping feature (not shown).
The robotic head 656 , best shown in FIG. 7B , comprises a housing 684 enclosing a holding chamber 685 for holding a single specimen container 500 therein. The robotic head further comprises a gripping mechanism 686 and a drive mechanism 688 to move the gripping mechanism 686 , and thereby a single specimen container 500 , into and out of the housing 684 and holding chamber 685 . The gripper mechanism 686 , as shown in 7 B, may comprise a spring clip 687 operable to snap over the lip of a specimen container 500 . After transferring the specimen container 500 to a holding structure 600 , as described elsewhere herein, the robotic head 656 , and thus the gripping mechanism 686 , can be raised or lowered relative to the holding structure 600 to release the specimen container 500 . The drive mechanism 688 further comprises a motor 690 , a guide rail 692 , a threaded gripper shaft 694 and a gripper drive block 696 , as shown in FIG. 7B . In operation, the motor 690 turns the threaded gripping shaft 694 , thereby moving the gripping drive block 696 , and thus the gripping mechanism 686 along the guide rail 692 .
Another design possibility of the transfer mechanism is shown in FIGS. 9A-9B . As shown in FIGS. 9A-9B an automated transfer mechanism 820 is incorporated into the detection system 100 shown in FIGS. 9A-9B in order to grasp or pick-up a container 500 from the entrance location or port 110 , and move or transfer a container 500 to a give receiving structure or well 802 , of an upper or lower drum holding structure 800 (described elsewhere herein). The automated transfer mechanism 820 in this embodiment is also operable to move a negative container 500 to a waste location and subsequently dropping or otherwise depositing the container 500 into a waste bin 146 , or operable to move a positive container to a positive container location (see, e.g., 130 in FIG. 1 ). To provide such movement, the transfer mechanism 820 includes a robotic head 824 which may include a gripping mechanism 826 for picking-up and holding a container 500 , and a rotatable support rod 828 that extends across the interior chamber 850 of the system 100 . As shown, the robotic head 824 is supported by, coupled to, and/or attached to the rotatable support rod 828 . In general, the gripping mechanism can be any known gripping mechanism in the art. In one embodiment, the gripping mechanism may be the gripping mechanism and drive mechanism described hereinabove in conjunction with FIGS. 6-8C . The robotic head 824 is moveable to any position along the rotatable support rod 828 . In operation, the support rod 828 can be rotated about its longitudinal axis, so as to orient the robotic head 824 towards either the upper or lower cylinder or drum holding structures 800 A, 800 B.
In one embodiment, the robotic head 820 is operable to pick-up a container 500 from the entrance location or port 110 and load the container 500 head-first (i.e., top portion 502 first) into the receiving structures or wells 802 of the drum holding structures 800 A, 800 B. This orientation exposes the bottom or base 506 of the container 500 to a detection unit 810 which can read the sensor 514 located at the bottom of the container 500 to detect microbial or microorganism growth within the container.
Yet another design possibility for the transfer mechanism is shown in FIGS. 17-21B . As shown in FIGS. 17-21B , the robotic transfer arm 700 will include one or more horizontal support structures 702 , one or more vertical support structures 704 , and a robotic head 710 that will include one or more features or devices (e.g., a gripping mechanism) to pick-up, grip and/or hold a specimen container 500 . The robotic head 710 can be supported by, coupled to, and/or attached to one of the horizontal supports and/or vertical supports. For example, in one embodiment, as shown in FIGS. 17-21B , the robotic transfer arm 700 comprises a lower horizontal support structure 702 B and a single vertical support structure 704 . Although, not shown, as one of skill in the art would appreciate an upper horizontal support structure (not shown), or other similar means can be used to further support or guide the vertical support structure. In general, any known means in the art can be used to move the robotic head 710 up and down the vertical support rail 704 (as represented by arrow 726 (see FIG. 18 )), and move the vertical support rail 704 back-and-forth along the horizontal support structure(s) 702 B (as represented by arrow 736 (see FIG. 20 )). For example, as shown in FIG. 20 , the robotic transfer arm 700 may further comprises a vertical drive motor 720 and vertical drive belt 722 that will operate to transfer or move the robotic head 710 up and down (arrow 726 ) the vertical support rail 704 to transfer or move a container 500 along (i.e., up and down) a vertical axis (i.e., the y-axis). The vertical support structure 704 may further comprise a vertical guide rail 728 and a robotic head support block 708 , as shown in FIG. 20 . Accordingly, the vertical support structure 704 , vertical guide rail 728 , vertical drive motor 720 and vertical drive belt 722 allow the robotic transfer arm 700 to move or transfer the robotic head support block 708 , and thus, the robotic head 710 and a specimen container 500 along the y-axis. Likewise, also as shown in FIG. 20 , the robotic transfer arm 700 may further comprise a first horizontal drive motor 730 , first horizontal drive belt 732 and horizontal guide rail 738 that will operate to move the vertical support structure 704 back-and-forth (i.e., from left-to-right and/or from right-to-left) along the horizontal guide rail 738 , and thus, along a first horizontal axis (i.e., the x-axis) within the housing 102 of the detection system 100 (see arrow 736 )). Accordingly, the horizontal support structure(s) 702 B, first horizontal drive motor 730 , first horizontal drive belt 732 and horizontal guide rail 738 allow the robotic transfer arm 700 to move or transfer a specimen container 500 along the x-axis. Applicants have found that by including a vertical support that is movable along a horizontal axis allows for an increased capacity within the detection system, as the robotic transfer arm is movable over an increased area within the instrument. Furthermore, Applicants believe a robotic transfer arm having a movable vertical support may provide a more reliable robot transfer arm.
As shown best in FIG. 17-21B , the automated transfer mechanism or robotic transfer arm 700 may further comprise a linear or horizontal slide 706 and pivot plate 750 . As shown, for example in FIGS. 17-20 , the linear or horizontal slide 706 supports the robotic head 710 and gripper mechanism 712 . The linear or horizontal slide 706 and robotic head 710 may be supported by, coupled to, and/or attached to, a robotic head support block 708 and vertical guide rail 728 (previously described). In accordance with this embodiment, the linear or horizontal slide 706 can be moved up and down (see FIG. 18 , arrow 726 ) along a vertical axis (i.e., the y-axis), via the a robotic head support block 708 and vertical guide rail 728 , to move or transfer the robotic head 710 and/or specimen container 500 up and down within the housing 102 of the detection system 100 (i.e., along the vertical axis (y-axis)). As shown in FIGS. 21A-21B , the linear or horizontal slide 706 may further comprises a pivot plate 750 comprising a pivot plate guide rail 752 , a pivot slot 754 and pivot slot cam follower 756 operable to allow the robotic head 710 to slide or moved along the linear or horizontal slide 706 , from front-to-back or from back-to-front (see FIG. 18 , arrow 746 ), to transfer or move a container 500 along a second horizontal axis (i.e., the z-axis). In accordance with this embodiment, a second horizontal drive motor or horizontal slide motor 760 and a slide belt (not shown) can be used to move the robotic head 710 along the z-axis. Accordingly, the linear or horizontal slide 706 , the horizontal slide motor and slide belt, allows the robotic head 710 to move or transfer a specimen container 500 along the z-axis. One or more sensors (see, e.g., 764 in FIG. 21A ) can be used to indicate the position of the robotic head 710 on the linear or horizontal slide 706 .
As shown in FIGS. 21A-21B , as the robotic head 710 is moved along the linear or horizontal slide 706 , pivot plate 750 and pivot plate guide rail 752 , the pivot slot 754 and pivot slot cam follower 756 rotate the pivot carriage 758 about or around a horizontal axis (i.e., the z-axis), and thus, rotates the robotic head 710 from a horizontal orientation (as shown in FIG. 21A ) to a vertical orientation (as shown in FIG. 21B ), or vice versa. As described elsewhere herein, the transfer of a container 500 from a vertical entry orientation to a horizontal orientation may be necessary for depositing or placing the container in a horizontally orientated receiving structure or well 602 of the holding structure or rack 600 . Accordingly, the pivot plate 750 , pivot slot 754 and pivot carriage 758 allow the robotic head 710 to re-orientate a specimen container 500 from a vertical orientation, as loaded (see, e.g., FIG. 18 ) to a horizontal orientation (as seen, e.g., in FIG. 21A ), thereby allowing a specimen container 500 to be transferred from an automated loading mechanism (see, e.g., 200 in FIG. 18 ) to a well in a holding structure (e.g., 602 and 600 in FIG. 18 ). As shown in FIG. 20 the automated transfer mechanism may also comprise one or more cable management chains 782 , for cable management within the detection system 100 , and a circuit board 784 for controlling the robotic transfer mechanism. In yet another embodiment, the robotic transfer arm 700 may further comprise a break mechanism 786 that can operate to break the vertical drive belt 722 , thereby preventing if from falling to the bottom of the instrument (e.g., due to a power outage).
The robotic transfer arm 700 may further comprise a gripping mechanism 712 to pick-up, grip or otherwise hold a specimen container 500 . As shown, for example in FIGS. 21A and 21B , the gripping mechanism may comprise two or more gripping fingers 714 . Furthermore, the gripping mechanism 712 may further comprise a linear actuator 716 and a linear actuator motor 718 which can operate to move the linear actuator to open and close the gripper fingers 714 . In operation, the actuator motor 718 can be used to move the linear actuator 716 of the gripper mechanism 712 thereby moving the gripper fingers 714 . For example, the linear actuator can be moved in a first direction (e.g., toward the motor) to close the fingers and grip the container 500 . Conversely, the linear actuator can be moved in a second direction (e.g., away from the motor) to open the gripper fingers and release the container 500 . Applicants have unexpectedly found that the use of one or more gripping fingers 714 allows the gripping mechanism 712 to accommodate (i.e., pick-up and/or hold) a large variety of different specimen containers 500 . Moreover, Applicants have found that by using gripper fingers 714 that extend from about one-quarter (¼) to about one-half (½) the length of the specimen container 500 , the gripper fingers will accommodate (i.e., pick-up and/or hold) a number of well known containers (e.g., long neck blood culture bottles) in the art.
As described further herein, the automated transfer mechanism or robotic transfer arm 700 can be placed under the control of a system controller (not shown) and programmed for specimen container 500 management (e.g., pick-up, transfer, placement and/or container removal) within the detection system 100 .
In yet another embodiment, as discussed further hereinbelow, the transfer mechanism 700 can be used for automated unloading of “positive” and “negative” specimen containers 500 .
Holding Means or Structure with Optional Agitation Means
The holding means or structure of the detection system 100 can take a variety of physical configurations for handling a plurality of individual specimen containers 500 so that a large number of containers (e.g., 200 or 400 containers, depending on the specific holding structures used) can be processed simultaneously. The holding means or structure can be used for storage, agitation and/or incubation of the specimen containers 500 . One possible configuration is shown in FIGS. 5A-5B , and another possible configuration is shown in FIGS. 9A and 9B . These configurations are provided by way of illustration and not limitation. As one of skill in the art will appreciate, other designs are possible and contemplated.
As shown in FIGS. 5A-5B and FIGS. 17-20 , one possible configuration uses a plurality of vertically stacked container holding structures or racks 600 each having a multitude of specimen container receiving structures or wells 602 each for holding individual specimen containers 500 . In accordance with this embodiment, two or more vertically stacked holding structures or racks 600 can be used. For example, from about 2 to about 40, from about 2 to about 30, from about 2 to about 20, or from about 2 to about 15 vertically stacked holding structures or racks can be used. Referring to FIGS. SA- 5 B and 17 - 20 , in this configuration the detection system 100 includes a climate controlled interior chamber 620 , comprising an upper interior chamber 622 and a lower interior chamber 624 , and a plurality of vertically disposed holding structures or racks 600 (e.g., as shown in FIGS. 5A-5B, 15 vertically stacked holding structures or racks 600 ) each having a plurality of individual container receiving structures or wells 602 therein. Each individual holding structure or rack 600 can comprise two or more container receiving structures of wells 602 . For example, each holding structure or rack 600 can comprise from about 2 to about 40, from about 2 to about 30, or from about 2 to about 20 receiving structures of wells 602 therein. In one embodiment, as shown in FIGS. 5A-5B , the receiving structures or wells 602 can comprise 2 rows of vertically aligned receiving structures or wells 602 . In an alternative embodiment, the receiving structures or wells 602 can be staggered, thus reducing the vertical height of each individual holding structure or rack 600 (see, e.g., FIG. 20 ), and thereby allowing for an increased number of total holding structures or racks 600 in a given vertical distance within the incubation chamber 620 . As shown, for example in FIGS. 5A-5B , the detection system comprises 15 holding structures or racks 600 each comprising two rows of 10 individual container receiving structures or wells 602 , thereby giving the system exemplified in FIGS. 5A-5B a total container capacity of 300 . In another possible design configuration, the detection apparatus may comprise 16 vertically stacked racks, each containing 25 receiving structures or wells, thereby giving a total container capacity of 400 .
Furthermore, each of the individual container receiving structures or wells 602 has a specific X and Y coordinate position or address, where X is the horizontal location and Y is the vertical location of each container receiving structure or well 602 . The individual wells 602 are accessed by a transfer mechanism, such as a robotic transfer arm, for example, as described hereinabove in conjunction with FIGS. 17-21 ). As shown in FIGS. 17-21 , the automated transfer mechanism 700 can operate to move the robotic head 710 , and thus, the specimen container 500 , to a specific of the X, Y positions in the rack 600 and deposit the container 500 therein. In operation, the automated transfer mechanism 700 can operate to pick-up a specimen container 500 at the entrance station 110 or the pick-up station 418 of the container locator device 400 , move a container 500 determined positive for microbial growth therein to a positive container or exit location 130 , and/or to move a container 500 determined negative for microbial growth to a negative container location or waste bin 146 .
In one embodiment, the entire holding structure or rack 600 can be agitated by an agitation assembly (not shown) to promote or enhance microorganism growth. The agitation assembly can be any known means or mechanism for providing agitation (e.g., a back-and-forth rocking motion) to the holding structures or racks 600 . In another embodiment, the holding structures or racks 600 can be rocked in a back-and-forth motion for agitation of the fluid contained within the containers. For example, the holding structures or racks 600 can be rocked back-and-forth from a substantially vertical position to a substantially horizontal position, and repeated to provide agitation of the fluid contained within the container. In yet another embodiment, the holding structures or racks 600 can be rocked back-and-forth from a substantially horizontal position to a vertical position 10 degrees, 15 degrees, 30 degrees, 45 degrees or 60 degrees from horizontal, and repeated to provide fluid agitation within the containers. In one embodiment, a racking motion from a substantially horizontal position to a vertical position from about 10 degrees to about 15 degrees from horizontal may be preferred. In still another embodiment, the holding structure or racks 600 can be rocked back-and-forth in a linear or horizontal motion to provide agitation of the fluid contained within the containers. In this embodiment, the holding structures or racks 600 and receiving structures or wells 602 can be orientated in a vertical, or alternatively in a horizontal position. Applicants have found that a linear or horizontal agitation motion, with the holding structures 600 , and thus the receiving structures or wells 602 and specimen containers 500 , in a horizontal orientation can provide substantial agitation with a relatively minimum energy input. Accordingly, in some embodiments, a horizontal holding structure or rack 600 orientation and a linear or horizontal agitation motion, may be preferred. Other means of agitating the holding structures or racks 600 , and thus, the fluid within specimen containers 500 are contemplated and would be well understood by one skilled in the art. These back-and-forth, liner and/or horizontal rocking motions can be repeated as desired (e.g., at various cycles and/or speeds) to provide agitation of the fluid within the containers.
One possible design for the agitation assembly is shown in conjunction with FIG. 26 . As shown in FIG. 26 , the agitation assembly 626 comprises one or more holding structures 600 comprising a plurality of holding wells 602 for holding a plurality of specimen containers 500 . The agitation assembly 626 further comprises an agitation motor 628 , an eccentric coupling 630 , a first rotation arm 632 , a second rotation arm or linkage arm 634 and a rack agitation bearing assembly 636 . In operation, the agitation motor 628 rotates the eccentric coupling 630 in an off-center motion thereby moving a first rotation arm 632 in an off-center circular or off-center rotational motion. The off-center rotational movement of the first rotation arm 632 moves a second rotation arm or linkage arm 634 in a linear motion (as represented by arrow 635 ). The linear motion of the second rotation arm or linkage arm 634 rocks the rack agitation bearing assembly 636 in a back-and-forth rocking motion, thereby providing a back-and-forth rocking agitation motion (represented by arrow 638 of FIG. 26 ) to the holding structures 600 .
In another possible design configuration, as shown in FIGS. 9A and 9B , the detection system 100 may includes upper and lower holding structures 800 A and 800 B in the form of cylindrical or drum structures containing a multitude of individual specimen container receiving structures or wells 802 for receiving one of the containers 500 . In this embodiment, the cylindrical or drum holding structures 800 A, 800 B each rotate about a horizontal axis to thereby provide agitation of the containers 500 . In accordance with this embodiment, each drum holding structure can comprise from about 8 to about 20 rows (e.g., from about 8 to about 20, from about 8 to about 18, or from about 10 to 1 about 6 rows), each comprising from about 8 to about 20 container receiving structures or wells 802 (e.g., from about 8 to about 20, from about 8 to about 18, or from about 10 to about 16 receiving structures of wells 802 ).
As described hereinabove, an automated transfer mechanism 820 is incorporated into the detection system 100 of FIGS. 9A-9B in order to grasp or pick-up a container 500 from the entrance location or port 110 , and move or transfer the container 500 to a give receiving structure or well 802 , of either the upper or lower drum holding structure 800 , and deposit the container 500 therein. The automated transfer mechanism 820 in this embodiment can further operate to move a negative container 500 to a waste bin 146 , or can operate to move a positive container to the positive container location 130 , shown for example, in FIG. 1 . Also, as previously described, the robotic head 820 of FIGS. 9A-9B can pick-up a container 500 from the entrance location or port 110 and load the container 500 head-first (i.e., top portion 502 first) into the receiving structures or wells 802 of the drum holding structures 800 A, 800 B. This orientation exposes the bottom or base 806 of the container 500 to a detection unit 810 which can read the sensor 514 located at the bottom of the container 500 to detect microbial or microorganism growth within the container.
As described elsewhere herein, positive and negative containers can be retrieved by the robotic transfer arm and transferred to other locations within the system. For example, a container determined “positive” for microbial growth can be retrieved and transferred via the transfer mechanism to a positive container location or port where a user or technician can easily remove the positive container. Similarly, a container determined “negative” for microbial growth after a designated time has passed can be transferred via the transfer mechanism to a negative container location or waste bin for disposal.
In one embodiment, the holding structure or rack 600 may further comprise a retention feature operable to hold or otherwise retain a specimen container 500 in the receiving structures or wells 602 of the rack 600 . As shown in FIGS. 27A-27C , the retention device 860 comprises a canted coiled spring 864 and a v-shaped holding plate 862 . In accordance with this embodiment, by using a canted coiled spring 868 , multiple points of the coiled spring contact the container surface to retain the bottle in the rack well 602 . The coils of the canted spring 864 are set at an angle relative to the vertical axis of the container, as shown in FIG. 27C , which shows exaggerated coils to demonstrate the coil angle relative to the vertical axis of the container. However, typically the canted spring 864 is a tightly coiled spring. For example the canted spring 864 can be at an angel of about 10 degrees to about 50 degrees, from about 20 degrees to about 40 degrees, or about 30 degree (as shown in FIG. 27C ), relative to the vertical axis of the container. The v-shaped holding plate 862 is capable of holding and/or retaining said canted coiled spring 864 relative to, or adjacent to the holding structure 600 . As shown, the holding plate 862 comprising a v-grooved retainer plate for retaining the canted coiled spring 864 . The v-groove retainer plate 864 prevents any movement of the spring 864 relative to the container 500 and/or holding structure 600 . Accordingly, unlike a traditional extension spring, which would typically contact a container at a single point (e.g., a flat leaf spring), the canted coiled spring 864 can be rigidly retained by the v-shaped groove 862 while the coils will deflect under pressure. The use of a canted spring 864 allows the load to be spread out, thereby providing uniform deflection.
As shown, e.g., in FIGS. 27A and 27C , the receiving structures or wells 602 further comprise one or more ribs 868 . In one design possibility, as shown in FIG. 27C , two of these ribs 868 are located directly opposite the canted coiled spring 864 . These two ribs 868 form a groove that functions to self-center the container 500 within the well 602 along a vertical centerline (not shown). In operation, the canted coiled spring 864 applies force to the container 500 wall, thereby holding or retaining the container securely within the well 602 of the rack 600 . In one embodiment, the two ribs 868 located opposite the coiled spring 864 can be spaced from 30 degrees to about 90 degrees apart, or from about 40 degrees to about 80 degrees apart. In another embodiment, the two ribs 868 located opposite the canted coiled spring 864 can be spaced about 60 degrees apart. Also, as shown in FIG. 27C , the holding structure may comprise a first row and a second row of parallel holding wells, the parallel holding rows being capable of, or operable for, holding a plurality of containers therein, and wherein the holding structure further comprises a first canted coiled spring located adjacent to the first row and a second canted coiled spring adjacent to the second row, wherein each of the canted coiled spring are operable for retaining the plurality of containers in said holding wells.
Using the canted coiled spring 864 , v-groove retainer 862 and two ribs 868 located opposite said canted coiled spring 864 , the bottle will always be held securely in the same location within the well 602 , regardless of any sideloads applied through agitation or during rack cell insertion. The canted coiled spring 864 and v-groove retainer 862 also allow for the use of a shorter depth holding well 602 and holding structure 600 . The shorter holding well 602 depth will allow for multiple container designs and container lengths to be retained equally well, as well as allow more of the container surface to be expose to the incubation air flow within the system.
As one of skill in the art would appreciate other possible designs or configurations for the holding structure or structures 600 and/or agitation assembly are possible and are considered part of present invention.
Detection Unit
The various possible design configurations of the detection system 100 , as shown in FIGS. 1-6, 9A-9B, 21A-21B and 27 , can include the use of similar detection means. In general, any known means in the art for monitoring and/or interrogating a specimen container for the detection of microbial growth can be used. As previously mentioned, the specimen containers 500 can be monitored continuously, or periodically, during incubation of the containers 500 in the detection system 100 , for the positive detection of microbial growth. For example, in one embodiment, a detection unit (e.g., 810 of FIG. 9B ) reads the sensor 514 incorporated into the bottom or base 506 of the container 500 . A variety of sensor technologies are available in the art and may suitable. In one possible embodiment, the detection unit takes colorimetric measurements as described in the U.S. Pat. Nos. 4,945,060; 5,094,955; 5,162,229; 5,164,796; 5,217,876; 5,795,773; and 5,856,175, which are incorporated herein. A positive container is indicated depending upon these colorimetric measurements, as explained in these patents. Alternatively, detection could also be accomplished using intrinsic fluorescence of the microorganism, and/or detection of changes in the optical scattering of the media (as disclosed, for example, in U.S. patent application Ser. No. 12/460,607, filed Jul. 22, 2009 and entitled, “Method and System for Detection and/or Characterization of a Biological Particle in a Sample.”). In yet another embodiment, detection can be accomplished by detecting or sensing the generation of volatile organic compounds in the media or headspace of the container. Various design configurations for the detection unit can be employed within the detection system. For example, one detection unit could be provided for an entire rack or tray, or multiple detection units could be provided per rack or per tray.
Climate-Controlled Interior Chamber
As previously described, the detection system 100 may include a climate-controlled interior chamber (or incubation chamber), for maintaining an environment to promote and/or enhance growth of any microbial agents (e.g., microorganisms) that may be present in the specimen container 500 . In accordance with this embodiment, the detection system 100 may include a heating element or hot air blower to maintain a constant temperature within said interior chamber. For example, in one embodiment, the heating element or hot air blower will provide and/or maintain the interior chamber at an elevated temperature (i.e., a temperature elevated above room temperature). In another embodiment, the detection system 100 may include a cooling element or cold air blower (not shown) to maintain the interior chamber at a temperature below room temperature. In accordance with this embodiment, the interior chamber or incubation chamber will be at a temperature of from about 18° to about 45° C. In one embodiment, the interior chamber can be an incubation chamber and can be maintained at a temperature from about 35° C. to about 40° C., and preferably at about 37° C. In another embodiment, the interior chamber may be maintained at a temperature below room temperature, for example from about 18° C. to about 25° C., and preferably at about 22.5° C. A particular advantage provided is the ability to provide a more constant temperature environment for promoting and/or enhancing microbial growth within a specimen container 500 . The detection system 100 accomplishes this by providing a closed system, in which automated loading, transfer and unloading of specimen containers 500 occurs without the need to open any access panels that would otherwise disrupt the incubation temperature (from about 30° to 40° C., preferably from about 37° C.) of the interior chamber 620 .
In general, the detection system 100 can employ any known means in the art for maintaining a climate-controlled chamber for promoting or enhancing microbial growth. For example, to maintain a temperature controlled chamber, one or more heating element or hot air blower, baffles and/or other suitable equipment known in the art, can be used to maintain the interior of the detection system 100 at the appropriate temperature for incubating the container and promoting and/or enhancing microbial growth.
Typically, one or more heating element or hot air blower under control of the system controller are used to maintain a constant temperature within the interior chamber 620 of the detection system 100 . As known in the art, the heating element or hot air blower can be employed in a number of locations within the interior chamber. For example, as shown in FIGS. 5 and 6 one or more heating elements or hot air blowers 740 can be positioned at the base of the holding structures or racks 600 , for directing warm air across the plurality of holding structures or racks 600 . A similar arrangement can be provided in the embodiments of FIGS. 9A and 9B (see, e.g., 840 ). The details of the incubation features are not particularly pertinent, and are known in the art, therefore a detailed description is omitted.
Controller and User Interface
The detection system 100 will include a system controller (e.g., a computer control system) (not shown) and firmware for controlling the various operations and mechanisms of the system. Typically, the system controller and firmware for controlling the operation of the various mechanisms of the system can be any known conventional controller and firmware known to those of skill in the art. In one embodiment, the controller and firmware will performs all operations necessary for controlling the various mechanisms of the system, including: automated loading, automated transfer, automated detection and/or automated unloading of specimen containers within the system. The controller and firmware will also provide for identification and tracking of specimen containers within the system.
The detection system 100 may also include a user interface 150 and associated computer control system for operating the loading mechanism, transfer mechanism, racks, agitation equipment, incubation apparatus, and receiving measurements from the detection units. These details are not particularly important and can vary widely. When a container is detected as being positive, the user can be alerted via the user interface 150 and/or by the positive indicator 190 (see, e.g., FIG. 1 ) becoming active (i.e., an indicator light turning on). As described herein, upon a positive determination, the positive container can be automatically moved to a positive container location 130 , shown for example in FIGS. 1-3, 10-11 and 22-24 for retrieval by a user.
The user interface 150 may also provide an operator or laboratory technician with status information regarding containers loaded into the detection system. The user interface may includes one or more of the following features: (1) Touch screen display; (2) Keyboard on touch screen; (3) System status; (4) Positives alert; (5) Communications to other systems (DMS, LIS, BCES & other detection or identification Instruments); (6) Container or bottle status; (7) Retrieve containers or bottles; (8) Visual and audible Positive Indicator; (9) USB access (back ups and external system access); and (10) Remote Notification of Positives, System Status and Error Messages. In another embodiment, as shown in FIGS. 22-23 , a status update screen 152 can also be used. The status update screen 152 can be used to provide status information regarding containers loaded into the detection system, such as, for example: (1) container location within the system; (2) container information, such as, patient information, sample type, input time, etc.; (3) positive or negative container alerts; (4) interior chamber temperature; and (5) an indication that the waste bin is full and needs to be emptied.
The particular appearance or layout of the detection system and user interface 150 , and/or status update screen 152 , is not particularly important, and can vary widely. FIGS. 1-2 show one possible embodiment, which is provided by way of illustration and not limitation. FIGS. 22-23 show another possible embodiment, which is also provided by way of illustration and not limitation.
Automated Unloading
The detection system 100 may also provide for automated transfer or automated unloading of “positive” and “negative” specimen containers 500 . As previously described, containers in which a microbial agent is present are termed “positive” containers, and containers in which no microorganism growth is detected after a given time period are termed “negative” containers.
Once a container is detected as positive, the detection system will notify the operator of the results through an indicator (e.g. visual prompt 190 ) and/or through notification at the user interface 150 . Referring now to FIGS. 1-3 and 5A-5B , positive bottles can be automatically retrieved via the transfer mechanism 650 (e.g., robotic transfer arm) and placed in a designated positive container area, such as a positive container location or exit port 130 . This positive container area will be located outside of the instrument housing for easy user access to the container. In a one embodiment, the container will be placed in a vertical orientation within the positive container area. In one design configuration, the automated unloading of a positive container will employ the use of a transfer tube (not shown) through which a positive container (e.g., a positive blood culture bottle) can travel to be relocated to a designated positive container location or exit port 130 . In accordance with this design feature, the transfer mechanism (e.g., the robotic transfer arm) will drop or otherwise deposit the positive specimen container into a top end of the transfer tube, and the container will travel through the transfer tube via gravity to the positive container location or port 130 . In one embodiment, the transfer tube (not shown) can hold one or more “positive” specimen containers therein. For example, the transfer tube (not shown) can hold from about 1 to about 5, from about 1 to about 4, or from about 1 to about 3 “positive” specimen containers. In another embodiment, for example as shown in FIGS. 22-24 , the positive container location or exit port 130 may comprise holding wells for one or more “positive” specimen containers, for example, two holding wells for separately holding two “positive” specimen containers.
In another embodiment of the detection system 100 , negative containers can be transferred by the transfer mechanism 700 (e.g., robotic transfer arm) from the holding structure or rack 600 to a negative container location, such as a waste bin 146 . Typically, the containers will be released from the robotic transfer arm and dropped into the waste bin 146 , however other embodiments are contemplated and should be apparent to one of skill in the art. In one design configuration, the automated unloading of a negative container will employ the use of a transfer tube (not shown) through which a negative container (e.g., a negative blood culture bottle) can travel to be relocated to a designated negative container location, such as a waste bin 146 . In accordance with this design feature, the transfer mechanism (e.g., the robotic transfer arm) will drop or otherwise deposit the negative specimen container into a top end of the transfer tube, and the container will travel through the transfer tube via gravity to the negative container location or waste bin 146 . The detection system 100 may also include an access door 140 or drawer 142 that opens to provide user access to the negative container location, such as a negative container waste bin 146 . In another embodiment, the waste bin 146 may include a scale to weigh the waste bin 146 . As one of skill in the art would appreciate, by monitoring the weight of the waste bin 146 , the system controller (not shown) can determine how full the waste bin 146 is, and can optionally provide a signal (e.g., at the user interface 150 ) indicating to the user or technician that the waste bin 146 is full, and thus, needs to be emptied.
Automated Laboratory System
As noted above, the detection system 100 of this disclosure can take on a variety of different possible configurations. One such configuration, particularly suited for high volume implementations, is shown in FIG. 24 . As shown in FIG. 24 , the detection system 100 A can be employed in an automated microbiology laboratory system. For example, the detection instrument 100 can be included as one component of an automated laboratory system. In this embodiment, the detection instrument 100 A can be linked or “daisy chained” to one or more additional other analytical modules or instruments for additional testing. For example, as shown in FIG. 24 , the detection instrument 100 A can be linked or “daisy chained” to a second detection unit 100 B. However, in other embodiments, the detection instrument can be “daisy chained” or otherwise linked to one or more other systems or modules. These other systems or modules can include, for example, identification testing systems such as the VITEK or VIDAS systems of the assignee bioMerieux, Inc., a gram stainer, a mass spectrometry unit, a molecular diagnostic test system, a plate streaker, an automated characterization and/or identification system (as disclosed in U.S. patent application Ser. No. 60/216,339, entitled “System for Rapid Non-invasive Detection of a Microbial Agent in a Biological Sample and Identifying and/or Characterizing the Microbial Agent”, which was filed May 15, 2009) or other analytical systems.
Referring now to FIG. 24 , an automated laboratory system can comprise a first detection system 100 A, and a second detection system 100 B. In other embodiments, the automated laboratory system can comprise a first detection system 100 A, a second detection system 100 B, and an automated characterization/identification system (not shown). In accordance with this embodiment, positive containers can be moved or transferred from the first detection system 100 A to the second detection system 100 B, and/or subsequently to the automated characterization/identification system, using a system transfer device 440 . In other embodiments, the first detection system 100 A can be coupled to a microorganism identification module or an antimicrobial susceptibility module (not shown).
The system transfer device or mechanism for transferring a container from a first instrument to a second instrument may comprise: (a) providing a first instrument, a second instrument, and a container located within said first instrument; (b) a first locator device coupled to said first instrument and operable for moving said container to one or more work-flow stations; (c) a transport mechanism or conveyor belt coupled to said second instrument and located juxtaposed to said first locator device; and (d) a pusher arm operable to move or push said container from said first locator device to said transport mechanism and thereby transferring said container from said first instrument to said second instrument. In another embodiment, the first and second instruments can be culture instruments and the container can be a specimen container. In yet another embodiment, the transport mechanism comprises a first transport mechanism or conveyor belt coupled to said first instrument, a first locator device coupled to said first instrument, a second transport mechanism or conveyor belt coupled to said second instrument, a second locator device coupled to said second instrument, and a pusher arm for transferring a container from said first locator device to said second transport mechanism or conveyor belt thereby transferring said container from said first instrument to said second instrument. In still a further embodiment, the transfer mechanism may comprises a transfer bridge coupled to said first and said second instruments thereby coupling or linking the first and second instruments. The transfer bridge will comprise a first end located juxtaposed to said first locator device and a second end located juxtaposed to said second transport mechanism or conveyor belt. The transfer bridge links the first instrument and the second instrument and provides a mechanism or means for transferring a container from the first instrument to the second instrument. Accordingly, in this embodiment, the transfer mechanism may further comprises a transfer bridge linking said first instrument to said second instrument, wherein said transfer bridge comprises a first end located juxtaposed to said first locator device and a second end located juxtaposed to said second transport mechanism, thereby linking said first locator device and said second transport mechanism, and wherein said pusher arm is operable to push said container across said transfer bridge, thereby transferring said container from said first instrument to said second instrument.
As shown in FIGS. 24-25C two detection systems 100 A and 100 B are “daisy chained” together by system transfer device 441 . This allows containers to be transferred from one detection system to another in case the first one is full. A similar system transfer device may also be provided for subsequent transfer of the specimen container 500 from the second detection system 100 B to a subsequent systems or modules, as described elsewhere herein. The system transfer mechanism 441 comprises a first container locator device 400 A having a transfer station 420 for transferring a container to a second or downstream instrument. The system transfer mechanism 441 also comprises a pusher arm 444 operable controlled by a pusher motor 442 and a transfer bridge 446 , as shown in FIG. 24-25C . As shown, the pusher arm 444 may comprise a pair of parallel arms. In operation, when a container to be transferred is moved by the transfer station 420 of the first container locator device 400 A, a pusher arm 444 is activated to push or move the container from the transfer station 420 , across a transfer bridge 446 , to the down-stream detection system 100 B. As shown, the pusher arm 444 is connected to a pusher motor 442 via a pusher arm support structure 445 . FIGS. 25A-C show the transfer of a container from the transfer station 420 of the first detection system 100 A to the conveyor belt 206 B (see FIG. 24 ) of the second detection system 100 B, and show the container in: (1) a first position ( FIG. 25A ) as the pusher arm 444 begins to push the container across the transfer bridge 446 ; (2) a second or intermediate position ( FIG. 25B ) as the container crosses the transfer bridge 446 ; and (3) a final position ( FIG. 25C ) as the container arrives at the conveyor belt (not shown) of the down-stream detection system 100 B. Furthermore, as shown in FIGS. 25A-25C , the system transfer device 440 may further comprise one or more locator device guide rails 450 attached to a base plate of the locator device 404 via one or more guide rail supports 452 , and/or bridge guide rails 446 , 448 , to guide the container from the first locator device 400 A and across the bridge 446 to the conveyor belt 206 B (see FIG. 24 ) of the automated loading mechanism 200 B of the down-stream detection system 100 B. The transfer of a container from the first detection system 100 A to the second or down-stream detection system 100 B, via the operation of the first container locator device 400 A and pusher arm 444 , can be controlled by the system controller. Typically, as shown in FIG. 24 , only the first detection system 100 A needs to include a user interface 150 . The first 100 A and second 100 B detection systems may further comprise status screens 152 A, 152 B, positive container ports 130 A, 130 B, lower access panels 140 A, 140 B, automated loading mechanisms 200 A, 200 B and conveyor belts 206 A, 206 B.
Further, in accordance with this embodiment, positive containers can be transferred to other systems in the automated laboratory system. For example, as shown in FIG. 24 , a container determined positive in the first detection system 100 A can be transferred to the second detection system 100 B and/or subsequently to an automated characterization/identification system (not shown) for automated characterization and/or identification of the microbe therein.
As one of skill in the art would appreciate other possible designs or configurations for the automated laboratory system are possible and are considered part of this invention.
Method for Detection of Microorganism Growth
In one embodiment, a method for detection of microorganism growth in an automated detection system is described herein. In some embodiments, the method includes: (a) providing a specimen container comprising a culture medium for promoting and/or enhancing growth of said microorganism; (b) inoculating said specimen container with a test sample to be tested for the presence of a microorganism; (c) loading said inoculated specimen container into said detection system using an automated loading mechanism; (d) transferring said specimen container to a holding structure located within said detection system using an automated transfer mechanism, said holding structure comprising a plurality of wells for holding one or more of said specimen containers; and said holding structure optionally providing agitation of said specimen containers to promote and/or enhance microorganism growth therein; (e) providing a detection unit for detecting microbial growth in said specimen container by detecting one or more by products of microorganism growth within said container; and (f) detecting growth of a microorganism using said detection unit and thereby determining said container positive for microorganism growth.
The method of operation of the detection system 100 will now be described with reference to FIG. 30 . After inoculation of a specimen container 500 with a sample to be tested (e.g., by a laboratory technician or doctor) the specimen container 500 is delivered to the automated loading mechanism 200 , for automated loading of the specimen container 500 into the detection system 100 .
At step 540 , the specimen container 500 is loaded into the detection system 100 , e.g., by placing the container onto a loading station or area 202 of a transport mechanism 204 , as shown for example in FIG. 1 . The specimen container 500 is then moved by the transport mechanism 204 (e.g., a conveyor belt) to an entrance location or port 110 , and subsequently through said entrance location or port 110 and into the detection system 100 , thereby automatically loading the specimen container 500 into the detection system 100 .
At step 550 , an automated transfer mechanism 700 , such as a robotic transfer arm, as shown for example in FIGS. 5A-5B , can then be used to transfer the container 500 to, and deposit the container in, a holding structure or rack 600 contained within the interior chamber 620 of the detection system 100 .
At step 560 , the specimen container 500 is incubated within the detection system 100 . The detection system 100 optionally provides for agitation (e.g., using an agitation assembly) of the holding structures or racks 600 , and/or one or more warm air blowers (see, e.g., 740 in FIGS. 5A-5B ) to provide a temperature controlled environment, to promote and/or enhance microbial growth within the specimen container 500 .
At step 570 , the specimen container 500 is read by a detection unit (see, e.g., 810 in FIGS. 9A and 9B ) to determine if the specimen container 500 is positive for microbial growth.
At step 580 , the reading of the specimen container is analyzed to determine if the container is positive for the growth of a microbial agent (e.g., a microorganism) therein. If not, the processing proceeds along the NO branch 582 and a check is made if a timer has expired (step 584 ). If the timer has expired, the container is deemed negative and the container is transferred to the waste container 146 (see for example FIG. 1 ) at step 586 . Otherwise, the incubation continues and the reading of the specimen container 500 (step- 580 ) continues periodically.
If at step 580 , if the specimen container 500 is determined to be positive, the processing proceeds to the YES branch 590 . In one embodiment, the specimen container 500 is moved or transferred using the automated transfer mechanism (e.g., the container is automatically unloading, as described elsewhere herein) to the positive container location or port 130 (see for example FIG. 1 ) at step 594 for user access to the container and/or further processing. In another embodiment, the specimen container can be transferred using a system transfer device to another detection instrument and/or another analytical system (e.g., to an automated characterization and/or identification system) for further processing.
Method for Transferring Specimen Containers between Apparatuses
In one embodiment, a method for transferring specimen containers between automated microbial detection apparatuses is provided. In some embodiments, the method includes transporting a specimen container in a locator well to a container transfer station in a first automated detection apparatus; sensing the specimen container at the container transfer station using a first sensor; transferring the specimen container from the container transfer station of the first automated microbial detection apparatus to an automated loading mechanism of a second automated microbial detection apparatus; detecting that the specimen container is positioned over the automated loading mechanism of the second automated microbial detection apparatus using a second sensor; and releasing the specimen container onto the automated loading mechanism of the second automated microbial detection apparatus.
A method 900 for transferring specimen containers will now be described with referenced to FIG. 31 . After inoculation of a specimen container with a sample to be tested (e.g., by a laboratory technician or doctor), in some embodiments the specimen container is delivered to the automated loading mechanism for automated loading of the specimen container into the detection system. As discussed herein and shown in block 902 , the automated loading mechanism transports the specimen container in a locator well of the container locator device to a container transfer station in a first automated detection apparatus.
In some embodiments, the specimen container is loaded onto a conveyor belt that advances towards the specimen container locator device. As the specimen container approaches the specimen container locator device, guiderails direct the specimen containers, one at a time, into a locator well of the specimen container locator device. The container locator device rotates and in this manner makes new locator wells available for specimen containers. As shown in FIGS. 25A-25C , the locator wells are concave and sized to receive a specimen container through an opening in the side of the locator well.
In some embodiments, the container locator device then rotates to a work-station, such as a container transfer station, where the specimen container in the locator well can be transferred to a downstream instrument. For example, the container locator device may rotate clockwise to a work-station that is configured with a transfer arm and a first sensor. In one embodiment, the container locator device advances the specimen container to the container transfer station, and the first sensor detects the presence of the specimen container. The different elements described here may be operatively connected via one or more system controllers, such as processors, that are configured to receive input from the sensors and control the various moving elements.
In some embodiments, the method includes sensing the specimen container at the container transfer station using a first sensor, as shown in block 904 . The first sensor may be an optical sensor, an inductive sensor, capacitive sensor, or a magnetic sensor. In this manner, the type of sensing may vary based on the specimen container used, the needs to the operator, and/or the type of sensor. In some embodiments, the sensor is continually sensing for the presence (or absence) of an object. In other embodiments, the sensor is intermittently or regularly detecting the presence (or absence) of an object.
In some embodiments, the sensor is positioned to detect the presence of the specimen container when it is being received by the container transfer station, i.e., not fully seated in the container transfer station. In this embodiment, the sensor detects the specimen container as it enters the container transfer station. In further embodiments, the sensor is positioned to only detect the presence of the specimen container when it is fully received into the container transfer station. For example, the sensor may detect an edge of the specimen container that is only detectable when the specimen container is fully seated in the container transfer station and capable of being transferred by the transfer arm.
In one embodiment, the method includes transferring the specimen container from the container transfer station of the first automated microbial detection apparatus to an automated loading mechanism of a second automated microbial detection apparatus, as shown in block 908 . In some embodiments, the specimen container is transferred using a transfer arm, as described in association with FIG. 25D . In this embodiment, the transfer arm grasps the specimen container and moves it between the detection instrument on which it is currently placed and onto the automated loading mechanism of a second, downstream instrument.
In some embodiments, transferring the specimen container includes lifting the specimen container at the container transfer station using the transfer arm, as shown in block 906 . For example, the specimen container may be lifted a small distance off the of the floor of the container transfer station to before transferring the downstream instrument. In this example, the raised specimen container assists in transferring between units because the units may not be at the same level. If this occurs, there may be a drop or a ridge between the first unit and the downstream unit, which could cause the specimen container to fall over during transfer. To solve this issue, lifting the specimen container a predetermined distance can reduce falls during the transfer of the specimen container.
In one embodiment, the transfer arm also includes a gripping mechanism, and the method includes gripping the specimen container prior to lifting the specimen container. In one embodiment, the specimen container is gripped using opposing paddles that wrap at least partially around the circumference of the specimen container.
In further embodiments, the method includes detecting that the specimen container is positioned over the automated loading mechanism of the second automated microbial detection apparatus using a second sensor, as shown in block 910 . In some embodiments, the second sensor activates after the first sensor detects the presence of the specimen container in the container transfer station. In one embodiment, the method includes detecting the cap of the specimen container. In this embodiment, the second sensor is positioned to detect the cap so that the system can trigger an alarm if the specimen container has fallen over. In other words, the specimen container may have transferred between the first instrument and the downstream instrument, but the specimen container tipped or fell over for some reason. In one embodiment, the method includes triggering an alarm when the second sensor does not detect the specimen container after the first sensor detects the specimen container. The alarm may be a notification, or a visual and/or audible alarm.
In further embodiments, the method includes releasing the specimen container onto the automated loading mechanism of the second automated microbial detection apparatus, as shown in block 912 . In some embodiments, releasing includes opening the gripping mechanism and allowing the specimen container to contact the automated loading mechanism. In one embodiment, the specimen container is released while raised so that it descends to the automated loading mechanism. In this embodiment, friction between the opposing paddles and specimen container may slow the descent. In further embodiments, the transfer arm may lower the specimen container to the automated loading mechanism before releasing the specimen container.
In one embodiment, the method includes activating the automated loading mechanism of the second automated microbial detection apparatus prior to releasing the specimen container onto the automated loading mechanism. It has been found that have the automated loading mechanism moving prior to releasing the specimen container makes it less likely that the specimen container will tip over after being released. In some embodiments, the automated loading mechanism is activated within a short period of time, e.g., 500 msec, after the gate opens.
In further embodiments, the method includes retracting the transfer arm to a pick-up position in the container transfer station when the second sensor detects that the specimen container has departed the transfer arm. In this embodiment, the method include the following steps: detecting the cap of the specimen container using the second sensor, detecting the departure of the specimen container using the second sensor, and retracting the transfer arm in response to detecting the departure of the specimen container. In some embodiments, there is a delay in retracting the transfer arm to reduce the likelihood that the transfer arm will knock over the specimen container on the automated loading mechanism.
In one embodiment, the method includes preventing backwards motion of the specimen container after the specimen container is released onto the automated loading mechanism of the second automated microbial detection apparatus. In this embodiment, a gate may be placed between the first instrument and the downstream instrument. When the specimen container is transferred from the first instrument to the downstream instrument, the gate may actively open or may be passively pushed open by the specimen container. In some embodiments, the gate is on a hinge and is both sized and positioned so that it can return to a neutral position between the first and downstream instrument after the specimen container has passed the gate. In this manner, the gate blocks backwards motion of the specimen container towards the first instrument. For example, if the specimen container is unbalanced it is unable to fall backwards into the first instrument after being released because the gate prevents it. Further, in some embodiments, the automated loading mechanism is capable of running in reverse, i.e., away from the entrance, and the gate would prevent the specimen container from falling off the automated loading mechanism or jamming the container transfer station of the first unit in this situation.
In some embodiments, the automated loading mechanism is activated when a third sensor determines that a gate between the container transfer station of the first automated microbial detection apparatus and the automated loading mechanism of the second automated microbial detection apparatus is away from a home position. In this embodiment, movement of the gate triggers the movement of the automated loading mechanism.
In further embodiments, the method includes halting movement of the automated loading mechanism of the second automated microbial detection apparatus when a fourth sensor positioned proximate to an entrance location of the second automated microbial detection apparatus does not detect a specimen container for a predetermined period of time. This step in the method is designed to reduce unnecessary use of the automated loading mechanism on the downstream instrument. The fourth sensor determines monitors for specimen containers and if no specimen container is detected for a predetermined period of time, the automated loading mechanism is halted. In this embodiment, the period of time may be based on the speed and/or length of the automated loading mechanism.
Method for Load Balancing Specimen Containers Between a Plurality of Automated Detection Apparatuses
In one embodiment, a method for load balancing between a plurality of automated detection apparatuses is provided. In some embodiments, the method includes receiving a specimen container at a container pick-up station in a first automated detection apparatus; determining a loading ability of the first automated detection apparatus; determining a loading ability of one or more downstream automated detection apparatuses; determining a transfer status of the first automated detection apparatus; determining a transfer status of the one or more downstream automated detection apparatuses; determining cell availability in the first automated detection apparatus and in the one or more downstream automated detection apparatuses; and transferring the specimen container from the first automated detection apparatus to a downstream automated detection apparatus when a first ratio of effective available cell count to effective capacity in the first automated detection apparatus is less than a second ratio of total effective available cell count to total effective capacity of a sum of the first automated detection apparatus and the one or more downstream automated detection apparatuses.
A method 920 for load balancing between a plurality of automated detection apparatuses will now be described with referenced to FIG. 32 . After inoculation of a specimen container with a sample to be tested (e.g., by a laboratory technician or medical professional), in some embodiments the specimen container is delivered to the automated loading mechanism of an automated detection apparatus for automated loading of the specimen container into the detection system.
In some embodiments, the specimen container is loaded onto a conveyor belt that advances towards the specimen container locator device. As the specimen container approaches the specimen container locator device, guiderails direct the specimen containers, one at a time, into a locator well of the specimen container locator device. The container locator device rotates and in this manner makes new locator wells available for specimen containers. As shown in FIGS. 25A-25C , the locator wells are concave and sized to receive a specimen container through an opening in the side of the locator well.
In some embodiments, the container locator device then rotates to a work-station, such as an imaging station and/or a container pick-up station. In some embodiments, the specimen container is imaged at the imaging station and information regarding the specimen container is determined by the system controller. In one embodiment, the container locator device then rotates to the container pick-up station where the specimen container will either be loaded into the present automated detection apparatus or moved to a container transfer station to a downstream instrument.
In one embodiment, identifying the specimen container at the imaging work-station is the first step in loading the specimen container into an automated detection apparatus. When the specimen container is identified, e.g., via the bar code, the system controller can begin the process of determining where and how the specimen container will be incubated. In some embodiments, two or more automated detection apparatuses are arranged in a sequence so that a medical provider can scale the detection capability by adding additional units. As discussed in FIG. 31 , a system and method for transferring specimen containers between the two or more automated detection apparatuses. In some embodiments, the two or more automated detection apparatuses are functionally identical. In other embodiments, the two or more automated detection apparatuses differ in one or more characteristic. For example, the maximum capacity in the apparatuses may differ, the incubation temperature may differ, or the method of identifying a positive specimen container may differ.
In one embodiment shown in block 922 , the method includes receiving a specimen container at a container pick-up station in a first automated detection apparatus. In some embodiments, the specimen container is moved to a region where the system controller determines whether: (1) the automated transfer mechanism picks-up the specimen container to load the specimen container into the holding structure associated with the automated detection apparatus, or (2) moves the specimen to a container transfer station for downstream transfer of the specimen container. In some embodiments, receiving the specimen container means that the specimen container is in position for loading or transfer.
In some embodiments shown in block 924 , the method includes determining a loading ability of the first automated detection apparatus. As used herein, “loading ability” means whether the automated detection apparatus is physically capable of loading the specimen container into the holding structure. In other words, the system controller determines whether the automated transfer mechanism is functional. In some embodiments, the automated transfer mechanism may malfunction and it may not be possible to load specimen containers into the holding structure of the automated detection apparatus.
In one embodiment, the system controller determines the loading ability of the automated detection apparatus by testing movement of the automated transfer mechanism. In further embodiments, the system controller receives a notice when the automated transfer mechanism is malfunctioning. In some embodiments, the system controller determines whether the automated transfer mechanism is malfunctioning every time a specimen container is received in the container pick-up station. In other embodiments, the system controller checks whether a malfunction notice has been received and checks whether the automated transfer mechanism has been repaired when a new specimen container is received. It should be understood that automated transfer mechanism is only one element that may malfunction or prevent loading of the automated detection apparatus. Other elements, such as the holding structure, the agitation device, and/or the detection device may also be malfunctioning and therefore inhibit the loading ability of the automated detection apparatus.
In one embodiment shown in block 926 , the method includes determining the loading ability of one or more downstream automated detection apparatuses. Just as the automated detection apparatus into which the specimen container is originally loaded, the downstream automated detection apparatuses may also have a malfunction in their loading ability. For example, one of the downstream automated detection apparatuses may have a malfunctioning agitation device and therefore the loading ability of that automated detection apparatus is determined to be inhibited.
In further embodiments shown in block 928 , the method includes determining a transfer status of the first automated detection apparatus. As used herein, “transfer status” means the ability to transfer to and/or from an automated detection apparatus. The transfer status of the first automated detection apparatus will relate to the automated loading mechanism for loading the specimen container into the apparatus, the container locator device for moving the specimen container among one or more work-stations, and the container transfer station for transferring the specimen container to a downstream automated detection apparatus. In some embodiments, sensors and/or input from the elements of the first automated detection apparatus provide information to the system controller, which determines the transfer status of the first automated detection apparatus.
In some embodiments shown in block 930 , the method also includes determining a transfer status of the one or more downstream automated detection apparatuses. As with the first automated detection apparatus, the downstream automated detection apparatuses may be connected to a single system controller or each downstream apparatus may have its own system controller, each of which is linked in a wired or wireless network. The system controller can affirmatively check each downstream apparatus or monitor for changes in transfer status of each downstream apparatus.
In one embodiment, the method includes assigning a transfer status to the first automated detection apparatus and/or the one of more downstream automated detection apparatuses, the transfer status selected from the group consisting of active, disabled, load-only, and pass through. In one embodiment, the system controller assigns the transfer status to the detection apparatus based on data received from one or more elements of the detection apparatus. For example, when all elements are operating as expected in a detection apparatus, the system controller assigns the “active” status to the automated detection apparatus. If the automated transfer mechanism that transfers the specimen container into the holding apparatus is operational, but the container transfer station for transferring the specimen container downstream is blocked, the system controller will assign the “load-only” status to the detection apparatus. If the ability to load specimen containers into the holding apparatus is not operational but the container transfer station is operational, then the system controller will assign the “pass through” status to the detection apparatus. If both the ability to load specimen containers into the holding structure and the transfer specimen containers to downstream detection apparatuses are not operational, then the system controller will assign the “disabled” status to the detection apparatus.
In some embodiments, transfer status is further divided into high and low status. For example, active status instruments may be further classified as active-high or active-low and load-only status instruments may be further classified as load-only high and load-only low. A low classification indicates that loading a specimen container into that instrument is possible but not preferred for some reason, such as greater temperature variation, inaccessibility, malfunction in some part of the instrument (e.g., agitator, imager, illumination bar, etc.), or some other reason that the instrument may not be preferred over other instruments in the grouping. If there are cells available in the plurality of instruments (including the local instrument) that have an active-high status or load-only high transfer status, then the effective available cell count and effective capacity of instruments with a low status (active-low or load-only low transfer status) are regarded as zero. In this way, the cells in active-low and load-only low instruments will not be regarded as available until the other instruments are full.
In some embodiments, an automated detection apparatus having an active status is determined to be capable of loading a specimen container into a well of the automated detection apparatus and is determined to be capable of transferring to and from the automated detection apparatus.
In further embodiments, an automated detection apparatus having a disabled status is determined to be incapable of loading a specimen container into a well of the automated detection apparatus and is determined to be incapable of transferring to and from the automated detection apparatus. If a downstream instrument has a transfer status of disabled, then the effective available cell count and effective capacity of that instrument and all of its downstream instruments are regarded as zero. An instrument may have a disabled status for a variety of reasons, such as because the robot and loader is not in active state and the status does not meet the conditions for pass through. This includes many conditions such as initialization, shutdown, low-power, open door flap, etc. Other reasons for a disabled status include a jam (including fallen bottle), being in jam recovery, or a rescan is occurring, the conveyor cover is open, the loader is in loading mode following the detection of the closing of the indexer cover, the indexer cover is open, or there is a request to open the door to the instrument from the graphical user interface.
In some embodiments, an automated detection apparatus having a load-only status is determined to be capable of loading a specimen container into a well of the automated detection apparatus and is determined to be incapable of transferring to a downstream automated detection apparatus. If an instrument has a transfer status of load-only high or load-only low, then the effective available cell count and effective capacity of all of its downstream instruments are regarded as zero.
In one embodiment, an automated detection apparatus having a pass through status is determined to be incapable of loading a specimen container into a well of the automated detection apparatus and is determined to be capable of transferring to and from the automated detection apparatus. If any instrument has a pass through status, then that instrument's effective available cell count and effective capacity are regarded as zero.
The system controller evaluates the elements of the detection apparatus, e.g., the automated loading mechanism, the automated transfer mechanism, the container transfer station, and the container locator device to determine whether the status of each automated detection apparatus in the chain of linked detection apparatuses. This information is then used to assist in load balancing the specimen containers between the plurality of the automated detection apparatuses.
In one embodiment shown in block 932 , the method includes determining cell availability in the first automated detection apparatus and in the one or more downstream automated detection apparatuses. As used herein, “cell availability” means the number of wells in the holding structure that are available for receiving a specimen container. In some embodiment, wells in the holding structure may already have a specimen container in them, may be malfunctioning for some reason, or may not be eligible for receiving a specimen container for another reason, in which case these cells were not be considered available.
In one embodiment, the system determines cell availability in the plurality of automated detection apparatuses by monitoring the wells using the system controller. In some embodiments, a well is determined to be unavailable when the automated transfer mechanism loads a specimen container into a well and the system controller determines that the detector is malfunctioning. In other embodiments, an ongoing count of available wells, occupied wells, and malfunctioning well is maintained by the system controller. In some embodiments, the cell availability is determined when each specimen container is received by the first automated detection apparatus. In one embodiment, cell availability is related to transfer status. For example, a downstream automated detection apparatus that has a load-only status will prevent the wells from any automated detection apparatuses downstream of the load-only apparatus from being available. In this scenario, the instruments downstream of the load-only apparatus may have open and operable wells but the system controller is unable to transfer specimen containers to them so they are considered unavailable.
In some embodiments, the method includes triggering an alarm when the cell availability in the first automated detection apparatus and in the one or more downstream automated detection apparatuses is determined to be zero. In this embodiment, the specimen container that has been loaded into the first automated detection apparatus cannot be loaded into a well until at least one well becomes available. In one embodiment, the alarm alerts a medical professional to the lack of well availability, e.g., via an electronic, visual, and/or audible alarm. In some embodiments, the alarm halts when a well becomes available, e.g., when a specimen container is determined to be negative and moved to trash or when an inoperable well becomes operable.
In some embodiments shown in block 934 , the method includes transferring the specimen container from the first automated detection apparatus to a downstream automated detection apparatus when a first ratio of effective available cell count to effective capacity in the first automated detection apparatus is less than a second ratio of total effective available cell count to total effective capacity of a sum of the first automated detection apparatus and the one or more downstream automated detection apparatuses. In some embodiments, transferring the specimen container to the downstream automated detection apparatus is accomplished using the container transfer station.
In one embodiment, the first ratio of effective available cell count to effective capacity in the first automated detection apparatus is a ratio of how many wells are available for the specimen container to how many wells are present in the first automated detection apparatus. In some embodiments, it is a measure of how full the automated detection apparatus is based on available wells and total number of wells.
In an embodiment, the second ratio of total effective available cell count to total effective capacity of a sum of the first automated detection apparatus and the one or more downstream detection apparatuses is a ratio of how many wells are available for the specimen container to how many wells are present in all of the plurality of automated detection apparatus. In this embodiment, the ratio is a measure of how full the plurality of detection apparatuses are on average. The method includes loading the specimen container into the first automated detection apparatus when the first ratio is less than the second ratio. In other words, the specimen container is loaded into the first automated detection apparatus if the first apparatus is less full than an average of the plurality of automated detection apparatuses. In this manner, the method balances the load of specimen containers in the plurality of automated detection apparatuses.
In some embodiments, the method includes loading the specimen container into the first automated detection apparatus when the first ratio is greater than or equal to the second ratio. If the first automated detection apparatus is fuller than the average apparatus, then the specimen container is transferred downstream. In some embodiments, when the specimen container is transferred a downstream automated detection apparatus, the system and method determines the ratios using the new downstream apparatus as the first automated detection apparatus and only counting downstream instruments in the plurality.
In some embodiments, the method includes overriding the transfer to the one or more downstream automated detection apparatuses when the cell availability in the first automated detection apparatus or in the plurality of detection apparatuses is determined to be within a predetermined number, e.g., about 5% or less than 20 total effective available cells in downstream instruments, of the total capacity of the first automated detection apparatus or the plurality of detection apparatuses. In one embodiment, specimen containers are passing through the system and may not be accounted for in well counts. When this occurs, a specimen container may be transferred downstream but there may be no well available for it. To alleviate this potential issue, in some embodiments, the method includes completely loading the first automated detection apparatus when it is determined to be close to being full. In this embodiment, the method would load the first automated detection apparatus and then move to the first downstream automated detection apparatus. If it is determined to be almost full, it would then fill that detection apparatus. In this way, the plurality of automated detection apparatuses are filled consecutively when the entire system is almost full. In one embodiment, this process overrides the low-status of downstream instruments and consecutively fills the detection apparatuses regardless of high or low status.
In one embodiment, transferring the specimen container from the first automated detection apparatus to a downstream automated detection apparatus reduces overall temperature variation within the automated detection apparatus and the one or more downstream automated detection apparatuses. In this embodiment, the temperature variation is reduced because specimen containers, which may influence the temperature within the incubation chamber, are balanced across the plurality of automated detection apparatuses. This reduction in temperature variation assists in maintaining consistent culture conditions within the plurality of automated detection apparatuses and may improve the detection accuracy of microorganisms being cultured in the specimen containers. Another advantage of the method of load balancing is that the wear and tear on the plurality of instruments is reduced and that it distributes the specimen containers more evenly to the waste receptacles. In this way, maintenance on the units is reduced. This also increases the unload capacity so that fewer positive bottles are kept at incubation temperatures after they have been identified as positive.
The present invention is described in part with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
The flowcharts and block diagrams of certain of the figures herein illustrate exemplary architecture, functionality, and operation of possible implementations of embodiments of the present invention. It should be noted that in some alternative implementations, the steps noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order or two or more blocks may be combined, depending upon the functionality involved.
The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.