EP4619767A2

EP4619767A2 - Devices and methods for transporting samples in diagnostic laboratory systems

Info

Publication number: EP4619767A2
Application number: EP23892546.5A
Authority: EP
Inventors: Klaus Kirchberg; Mark Edwards; Rayal PRASAD; Ankur KAPOOR
Original assignee: Siemens Healthcare Diagnostics Inc
Current assignee: Siemens Healthcare Diagnostics Inc
Priority date: 2022-11-16
Filing date: 2023-11-16
Publication date: 2025-09-24
Also published as: WO2024107950A3; CN120188047A; JP2025539774A; WO2024107950A2

Abstract

A method of operating a diagnostic laboratory system for analyzing a biological sample includes modeling in software a track in the diagnostic laboratory system as a plurality of blocks. At least one test to be performed on a biological sample is identified. A first software module is used to identify one or more instruments in the diagnostic laboratory system to perform the test, wherein the first software module is part of a program comprising a plurality of individual software modules in communication with each other. A second software module of the program is used to generate transport instructions to transport the biological sample via a sample container to the one or more instruments, wherein the transport instructions include instructions to transport the sample container through adjacent blocks. The sample container is transported to the one or more instruments in response to the transport instructions. Other methods and apparatus are disclosed.

Description

DEVICES AND METHODS FOR TRANSPORTING SAMPLES IN DIAGNOSTIC LABORATORY SYSTEMS

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/384,057, entitled “DEVICES AND METHODS FOR TRANSPORTING SAMPLES IN DIAGNOSTIC LABORATORY SYSTEMS” filed November 16, 2022, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.

FIELD

[0002] This disclosure relates to devices and methods for transporting sample containers in diagnostic laboratory systems.

BACKGROUND

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

[0004] The processing includes transporting the sample containers on tracks throughout the diagnostic laboratory systems. As the diagnostic laboratory systems increase in size, the complexities of the respective tracks increase. The complexities of transport programs that generate instructions to transport the sample containers also increase, which may slow down sample transportation or cause issues such as sample container collisions. Accordingly, systems and methods that provide simplified sample container transportation throughout laboratory systems are sought.

SUMMARY

[0005] According to a first aspect, a method of operating a diagnostic laboratory system for analyzing a biological sample is provided. The method includes providing a track in the diagnostic laboratory system, wherein sample containers containing biological samples are moveable on the track between a plurality of instruments; modeling in software via a computer the track as a plurality of blocks, wherein each block includes a movement pattern that indicates in which one or more directions the sample containers move into or out of the block; identifying at least one test to be performed on a biological sample; using a first software module to identify one or more instruments in the diagnostic laboratory system to perform the at least one test, the first software module being part of a program comprising a plurality of individual software modules in communication with each other; using a second software module of the program to generate transport instructions to transport the biological sample via a sample container to the one or more instruments, wherein the transport instructions include instructions to transport the sample container through adjacent blocks; and transporting the sample container to the one or more instruments in response to the transport instructions.

[0006] In another aspect, a method of operating a diagnostic laboratory system for analyzing biological samples is provided. The method includes providing a track in the diagnostic laboratory system, wherein the biological samples are moveable on the track by way of a plurality of sample carriers; representing the track as a graph via a computer, the graph comprising a plurality of nodes and edges, wherein each node represents a portion of the track configured to have only one sample carrier therein at a time and wherein each edge represents a movement pattern of a sample carrier to and from nodes connected thereto; identifying at least one test to be performed on a biological sample located in a sample container and transported via a sample carrier; identifying one or more instruments in the diagnostic laboratory system to perform the at least one test using a first software module, the first software module being part of a program comprising a plurality of individual software modules in communication with each other; generating transport instructions to transport the sample carrier to the one or more instruments using a second software module of the program, wherein the transport instructions include transporting the sample carrier between adjacent nodes; and transporting the sample carrier to the one or more instruments in response to the transport instructions.

[0007] In a further aspect, a diagnostic laboratory system for analyzing a biological sample is provided. The diagnostic laboratory system includes at least one instrument for preparing or testing the biological sample; a track configured to transport a sample container to and from the at least one instrument, wherein the sample container is configured to contain therein the biological sample to be analyzed. The diagnostic laboratory system also includes a computer configured to: model in software the track as a plurality of blocks, wherein each of the blocks includes a movement pattern that indicates in which one or more directions the sample container moves into or out of the block; identify at least one test to be performed on a biological sample by at least one instrument; and execute a program to control operation of the diagnostic laboratory system, the program having an architecture comprising a plurality of individual software modules in communication with each other, the plurality of individual software modules including: a first software module to identify one or more instruments in the diagnostic laboratory system to perform the at least one test, and a second software module to generate transport instructions to transport the biological sample to the one or more instruments, wherein the transport instructions include instructions to transport the biological sample from one block to an adjacent block.

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

BRIEF DESCRIPTION OF THE DRAWINGS

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

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

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

[0012] FIG. 1C illustrates an enlarged portion of the track of FIG. 1 B showing individual blocks and transportation components according to one or more embodiments. [0013] FIG. 1 D illustrates an isometric enlarged view of a portion of the track of FIG. 1A including two sample carriers holding sample containers, wherein the sample containers contain samples, and wherein the sample carriers are independently movable according to one or more embodiments.

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

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

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

[0017] FIG. 2 illustrates a block diagram of an embodiment of the track of the diagnostic laboratory system of FIG. 1A modeled in software as a plurality of adjacent blocks according to one or more embodiments.

[0018] FIGS. 3A-3D illustrate enlarged views of certain ones of the blocks of the diagnostic laboratory system of FIG. 1 and the block diagram of FIG. 2 according to one or more embodiments.

[0019] FIG. 4 illustrates a graph representation of the embodiment of the track of the diagnostic laboratory system of FIG. 1A as modeled in and analogous to the block diagram of FIG. 2 according to one or more embodiments.

[0020] FIG. 5 illustrates a block diagram of another embodiment of the track of the diagnostic laboratory system of FIG. 1A modeled in software as a plurality of adjacent blocks, wherein some of the blocks have different movement patterns than the blocks of FIG. 2 according to one or more embodiments.

[0021] FIGS. 6A-6D illustrate enlarged views of certain ones of the blocks of FIG. 5 according to one or more embodiments.

[0022] FIG. 7 illustrates a graph representation of the other embodiment of the track of the diagnostic laboratory system of FIG. 1 A as modeled in and analogous to the block diagram of FIG. 5 according to one or more embodiments. [0023] FIG. 8 illustrates an example of software layers that may be used in the architecture of the routing program of FIG. 1 A according to one or more embodiments.

[0024] FIG. 9 illustrates a routing program partitioned as separate and individually replaceable software modules, each of which respectively implements one of the software layers of FIG. 8 according to one or more embodiments.

[0025] FIG. 10 illustrates three-dimensional blocks representing a portion of a multi-level track that may move sample carriers and/or sample containers in three dimensions according to one or more embodiments.

[0026] FIG. 11 illustrates a flowchart of a method of operating a diagnostic laboratory system for analyzing a biological sample according to one or more embodiments.

[0027] FIG. 12 illustrates a flowchart of another method of operating a diagnostic laboratory system for analyzing biological samples according to one or more embodiments.

DETAILED DESCRIPTION

[0028] Automated diagnostic laboratory systems conduct clinical chemistry and/or assays to identify analytes or other constituents in biological samples such as blood serum, blood plasma, urine, interstitial liquid, cerebrospinal liquids, and the like. The samples are collected in sample containers and then delivered to a diagnostic laboratory system. The sample containers are subsequently loaded into a sample handler of the laboratory system. The sample containers are then transferred to sample carriers by a robot, wherein the sample carriers transport the sample containers to instruments and components of the laboratory system by way of a track where the samples are processed and analyzed.

[0029] Automated diagnostic laboratory systems may transport a plurality of sample containers to a plurality of different instruments via the track. A routing program determines routes on the track that each of the sample containers takes in order for the instruments to perform specific tests on the samples. Routing becomes more complex as more sample containers and testing capabilities are added to the laboratory systems. For example, sample containers may have to pass one another and/or yield to one another at certain times to arrive at specific instruments at specific times. The routing becomes even more complex when high priority samples are added because the routing must be updated so that low priority samples yield to the high priority samples.

[0030] Modular laboratory systems may be arranged in many different physical configurations (e.g., layouts of the track and instruments). Routing programs generally must be customized to the specific laboratory system configurations employed to route the sample containers properly. Customizing routing programs for each different configuration is difficult and increases the costs of implementing the laboratory systems.

[0031] Embodiments of the diagnostic laboratory systems and routing methods described herein use dynamic routing programs to transport sample containers throughout the diagnostic laboratory systems. In some embodiments, the software architecture employed in the laboratory systems is divided into multiple, independently-adjustable software layers, wherein each software layer may be designed, developed, tested, and executed independently of other software layers. Use of independently-adjustable software layers enables the same architecture to be scaled and/or customized for a wide variety of laboratory system configurations.

[0032] The independently-adjustable software layers may include one or more task layers and a physical transport layer. The one or more task layers determine which instruments and processes performed by those instruments are needed to complete testing on each of the samples. The physical transport layer determines the best routing for the sample carriers so that the samples are tested as determined by the one or more task layers. In such an architecture, only the physical transport layer may need to be customized to meet different laboratory system configurations. The physical transport layer may be executed in the routing program.

[0033] In some embodiments, the routing program may model in software a track of a diagnostic laboratory system as small “blocks,” wherein each block represents a portion of the track (e.g., configured to have only one sample carrier or one sample container therein at a time). Movement and tracking of the sample carriers may be based on the blocks. For example, mechanical transport mechanisms may be capable of moving sample carriers from one block to an adjacent block and stopping movement of the sample carriers in individual blocks. In some embodiments, a block representing a straight track portion of a track may be configured to have therein more than one sample carrier at the same time while blocks representing intersections of track portions may be configured to have only one sample carrier therein at a time.

[0034] Each block may have a movement pattern (e.g., forward, backward, left, right) attached to it that indicates in which one or more directions a sample carrier may move into or out of the block. For example, certain blocks may only receive sample carriers from the left and send them through only one sample carrier at a time to the right to an adjacent vacant block (e.g., a target block). A three-way intersection block may, for example, receive sample carriers from the left and send them through only one sample carrier at a time either to the right or down (as illustrated in a plan view) to adjacent target blocks. Movement from one block to an adjacent target block may only be permitted if the target block is vacant, which means that no other sample carrier is in the block. Otherwise, the sample carrier waits for that target block to become vacant. The blocks described herein are shown as being four-sided with movement patterns that are generally orthogonal. However, the apparatus and methods described herein are applicable to other block shapes, such as three-sided or more than four-sided blocks, and associated movement patterns (e.g., non-orthogonal movements, combinations of orthogonal and non- orthogonal movements, etc.).

[0035] Alternatively, instead of block modeling, the track layout of a diagnostic laboratory system may be represented as a graph of nodes and edges, wherein the nodes may be analogous to the blocks and the movement patterns may define the edges connecting the nodes (see, e.g., FIGS. 4 and 7, described below). The graph representation of a track layout is more general than a block model (using a Cartesian grid) of the track layout. For example, such a graph can represent a track layout with non-uniform block sizes. This duality of representations (Cartesian grid vs. graph) allows a flexible choice within the physical transport layer (described in more detail below) of the routing program for routing sample carriers throughout a laboratory system. Note that the following descriptions related to blocks and movement patterns of a block model of a track layout are also applicable to nodes and edges of a graph representation of the track layout. [0036] Returning to block modeling, in some embodiments, the blocks may be as small as possible to allow maximum traffic throughout the laboratory systems, but large enough so that each block may still have at least one sample carrier therein. In some embodiments, the minimum size of a block depends on the minimum allowable distance between two sample carriers on the track. The distance may depend, for example, on mechanical properties of the track, the sizes of the sample carriers, the magnitude of magnetic repulsion between the sample carriers (for those sample carriers that are moved in that way), and/or other constraints. The block representation of the track, including the movement pattern of each block, may then be derived from the physical layout of the track. The physical transport layer may then configure sample carrier routing based on the block representation of the track, wherein sample carrier routing is based on sensed motion of the sample carriers in and through the blocks or through and between the nodes of a graph.

[0037] The block modeling of the track provides for less complex sample carrier routing in the physical transport layer because the physical transport layer only considers motion of the sample carriers to and from adjacent blocks or adjacent nodes rather than start-to-finish movements of the sample carriers over the entire physical track. In addition, the block modeling reduces the complexity of path planning for the sample carriers as the blocks may instead be represented as nodes in a graph and provide a compact representation for path optimization. Furthermore, block control programs are configured to avoid collisions between sample carriers and overcrowding of the track because, in some embodiments, they allow only one sample carrier at a time to occupy a block or a node.

[0038] These and other systems and methods are described below in greater detail with reference to FIGS. 1A-12.

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

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

[0041] The track 110 is configured to allow the sample carriers 108 to move throughout the laboratory system 100 including to and from the sample handler 102C in response to transport instructions described herein. For example, the track 110 may extend proximate and/or around at least some of the instruments 102 as shown in FIG. 1A. The instruments 102 may have devices, such as robots (not shown in FIG. 1A), that transfer the sample containers 104 to and from the sample carriers 108. The track 110 may have electronic transport components (not shown in FIG. 1A) that move the sample containers 104 via the sample carriers 108 and/or monitor the locations of the sample containers 104 on the track 110.

[0042] The instruments 102 and the transport components may include or be coupled to a computer 120 configured to execute one or more programs that control operation of the laboratory system 100. The computer 120 may be configured to communicate with the instruments 102, the transport components, and other components of the laboratory system 100. The computer 120 may include a processor 122 configured to execute programs including programs other than those described herein. The programs may be implemented in computer code. In some embodiments, the computer 120 may be remote from the instruments 102.

Additionally, in some embodiments, the computer 120 may control the operation of a plurality of different laboratory systems. Thus, data generated by the laboratory system 100 may be stored and/or processed remotely.

[0043] The computer 120 may include or have access to memory 124 that may store one or more programs and/or data described herein. The memory 124 and/or programs stored therein may be referred to as non-transitory computer-readable mediums. The programs may be computer code executable on or by the processor 122.

[0044] The memory 124 may include a routing program 126 (e.g., computer code executable by the processor 122) configured to generate routes for individual sample containers and/or sample carriers 108. The routes may direct the sample containers 104 and/or the sample carriers 108 to specific ones of the instruments 102 to perform tests on samples in the sample containers 104.

[0045] The automated diagnostic laboratory system 100 may also include one or more segment controllers 128. Each segment controller 128 may control movement of sample carriers through one or more designated blocks of the track 110. Each segment controller 128 may include a processor, a transceiver or the like, and a memory storing a block control program 130 (e.g., computer code executable by the processor). The block control program 130 is configured to generate instructions that cause the sample containers 104 and/or the sample carriers 108 to move to and through the designated one or more blocks. Thus, each block control program 130 may generate instructions that activate certain components on the track 110 to move certain sample carriers 108 to and/or through the designated one or more blocks controlled by the segment controller 128 executing that block control program 130. Each segment controller 128 may be positioned around the track 110 at or near the block(s) it controls. Each segment controller 128 may communicate with computer 120 and/or each other via an Ethernet or other suitable network using a wired and/or wireless connection and may include components other than those described herein. In alternative embodiments, the functions performed by the segment controllers 128 may be performed by computer 120 or another central computer, and the respective block control programs 130 of the segment controller 128 may be stored in memory 124 and/or included in routing program 126.

[0046] A workstation 132 may be electrically coupled to and in communication with the computer 120. In some embodiments, the workstation 132 may be remote from the track 110. The workstation 132 may include at least a display 134 and a keyboard 136. The workstation 132 enables users of the laboratory system 100 to input data to the computer 120 and enables the computer 120 to output data to the user, such as by the display 134.

[0047] The track 110 as illustrated includes dashed lines to show the routes or paths that the sample carriers 108 (and thus the sample containers 104) may take within the laboratory system 100. As shown in FIG. 1A, the sample carriers 108 may take many routes throughout the laboratory system 100. The routing program 126 generates instructions that enable the sample carriers 108 to move to designated instruments at scheduled times to keep the laboratory system 100 operating efficiently. In some embodiments, the routing program 126 may determine the most efficient path for one or more of the sample carriers 108 given that there may be other sample carriers 108 travelling on the same path and/or to the same instruments. The segment controllers 128 (each executing a block control program 130) may activate transport components (described below) on the track 110 for blocks under their control to move the sample carriers 108 on the determined paths.

[0048] Additional reference is now made to FIG. 1 B, which illustrates an enlarged portion of the track 110. The track 110 has different segments 140 that enable the sample carriers 108 to move in at least an x-direction and a y-direction and change directions between the x-direction and the y-direction. The types of segments 140 include curved segments 140A that change the directions of the sample carriers 108 between x-directions and y-directions and vice versa. Other types of segments 140 are intersection segments 1406 that receive the sample carriers 108 from a first port and selectively output the sample carriers 108 to at least one of two other ports. The intersection segments MOB may also receive the sample carriers 108 from a first port or a second port and output the sample carriers 108 to a third port. The track 110 may also include straight segments 140C that continue motion of the sample carriers 108 in straight lines. [0049] Specific segments of the track 110 are described in detail below with reference to operation of the routing program 126. A first segment 142 is a straight segment extending in the x-direction. A second segment 144 is a curved segment extending in the y-direction and the x-direction. A third segment 146 is an intersection segment extending in the y-direction with a branch extending in the positive x-direction. A fourth segment 148 is another intersection segment extending in the x-direction with a branch extending in the negative y-direction. A fifth segment 150 is a curve and a sixth segment 152 is a curve that is a mirror image of the fifth segment 150.

[0050] The track 110 may include transport mechanisms 154 (a few labelled) configured to transport the sample carriers 108 on the track 110. Examples of the transport mechanisms 154 are illustrated in FIG. 1 B as being positioned below the track 110, however, in other embodiments, the transport mechanisms 154 may be located beside the track 110, above the track 110 or in any other suitable location. Examples of the transport mechanisms 154 are described below with reference to FIGS. 1 B-1G and may include movable belts and rollers (not separately shown), which use friction to move the sample carriers 108, and magnetic devices (see, FIGS. 1 F and 1 G, for example), which magnetically move the sample carriers 108 relative to the track 110. In yet other examples, the sample carriers 108 may be self- propelled on the track 110 (e.g., see, FIG. 1 D, for example) and, in some embodiments, may receive movement instructions wirelessly from the computer 120, segment controllers 128, and/or the transport mechanisms 154. The transport mechanisms 154 are not limited to the examples described above. Any suitable mechanism that transports the sample carriers 108 via the track 110 between blocks may be employed as the transport mechanisms 154. The transport mechanisms 154 may receive signals from the segment controllers 128 (via execution of block control programs 130) that cause the transport mechanisms 154 to operate.

[0051] The laboratory system 100 may also include a plurality of track sensors 156 (a few labelled) configured to identify the positions of the sample containers 104 and/or the sample carriers 108 on the track 110. The track sensors 156 are illustrated as straight or curved rectangular shapes adjacent the segments 140 of the track 110. However, in some embodiments, a track sensor 156 may be an integral part of a track segment. Track sensors 156 may be any device that senses or determines the positions of the sample carriers 108 and/or the sample containers 104 and then transmits the position information to an associated segment controller 128 for processing by a block control program 130 and/or to the computer 120 for processing by the routing program 126. In some embodiments, segment controllers 128 may forward position data received from the track sensors 156 to the computer 120. In some embodiments, the track sensors 156 may be small individual elements located adjacent the track 110. Examples of the track sensors 156 include optical devices that read indicia located on the sample carriers 108 and/or the sample containers 104, radio frequency identification devices (RFIDs) that read RFID tags located on the sample carriers 108 and/or the sample containers 104, etc. Other track sensors that determine positions of the sample containers 104 and/or the sample carriers 108 may be employed.

[0052] Additional reference is now made to FIG. 1C, which illustrates an enlarged portion of the first segment 142 transporting a first sample container 104A by way of a first sample carrier 108A. The track 110 is software modeled into a plurality of blocks 160. The shown portion of the first segment 142 is illustrated as having four blocks that are referred to individually as a first block 160A, a second block 160B, a third block 160C, and a fourth block 160D. Other numbers of blocks may be modeled for a given portion of the track 110. As described in greater detail below, the transport mechanisms 154 are configured to move the first sample carrier 108A and/or the first sample container 104A to and through adjacent blocks 160 (e.g., via linear motors, belts, signals and/or power applied to the first sample carrier 108A when self-propelled sample carriers are employed, etc.). For example, the transport mechanisms 154 may have hardware components associated with individual ones of the blocks 160. In the embodiment of FIG. 1 C, the transport mechanisms 154 are moving the first sample carrier 108A from the third block 160C to the fourth block 160D. In some embodiments, each of the blocks 160 may include an individual one of the transport mechanisms 154. In other embodiments, a plurality of the blocks 160 may be associated with a single transport mechanism, wherein the single transport mechanism is configured to transport the first sample carrier 108A between individual ones of the blocks 160.

[0053] In the embodiment of FIG. 1C, the track sensor 156 is illustrated as being portioned into a plurality of individual sensors. Each of the sensors may be configured to sense the position of the first sample carrier 108A in each of the blocks 160 and transmit the position information to one or more segment controllers 128 associated with blocks 160 and/or to computer 120 (for the routing program 126). A first sensor 156A senses the first sample carrier 108A in the first block 160A, a second sensor 156B senses the first sample carrier 108A in the second block 160B, a third sensor 156C senses the first sample carrier 108A in the third block 160C, and a fourth sensor 156D senses the sample carrier 108 in the fourth block 160D.

[0054] Additional reference is made to FIG. 1 D, which is an isometric enlarged view of a portion of the track 110 of FIG. 1C. In the embodiment of FIG. 1 D, the first sample container 104A supported by first sample carrier 108A contains a first sample 164A that may be analyzed by one or more of the instruments 102 (FIG. 1 A). The embodiment of FIG. 1 D also includes a second sample carrier 108B carrying a second sample container 104B. A second sample 164B is located in the second sample container 104B. The transport mechanisms 154 of FIG. 1 D may be a single mechanism that enables the first sample carrier 108A and the second sample carrier 108B to be independently moved in the second block 160B and the third block 160C (e.g., such as by magnetic induction). For example, the transport mechanisms 154 may move the first sample carrier 108A within the third block 160C while holding the second sample carrier 108B in the second block 160B. The track sensors 156 may be configured to identify the location of the first sample carrier 108A and the second sample carrier 108B on the track 110 and transmit position data to an associated segment controller 128 and/or the routing program 126. In some embodiments, the blocks 160 may be just slightly larger than the sample carriers 108. For example, the second block 160B and the third block 160C may be slightly larger than the footprint of the first sample carrier 108A and the second sample carrier 108B.

[0055] Additional reference is made to FIG. 1 E, which illustrates an embodiment of the first sample carrier 108A configured to be self-propelled. The first sample carrier 108A may include a housing 168 in which a motor 170 and a receiver 172 may be located. The motor 170 may be coupled to wheels 174 extending from the housing 168. The receiver 172 may receive transport instructions from one of the segment controllers indicating that the first sample carrier 108A is to move, such as from one block to an adjacent block. The receiver 172 may then activate the motor 170, which spins the wheels 174 and moves the first sample carrier 108A. In some embodiment, coils or the like may be in the transport mechanisms 154 and may generate electric fields that provide power to the motor 170. In some embodiments, appropriate electrical power may be provided to the motor 170 to move the first sample carrier 108A.

[0056] The routing program 126 generates paths to move the first sample carrier 108A and the second sample carrier 108B on the track 110 and instructions to move the first sample carrier 108A and the second sample carrier 108B. The instructions may then be parsed based on the specific blocks in the generated paths through which the first and second sample carriers 108A,B are to be transported. The parsed instructions may then be transmitted to the one or more segment controllers 128 that control movement of sample carriers through those specific blocks. The associated block control programs 130 of those one or more segment controllers 128 may then generate electric signals that cause the transport mechanisms 154 along the track 110 to move the first sample carrier 108A and the second sample carrier 108B through the specific blocks per the instructions. In embodiments where the sample carriers 108 are self-propelled, the segment controllers 128 may include one or more transceivers and/or radio transmitters that transmit instructions directly or indirectly to the first and second sample carriers 108A.B upon the segment controllers 128 receiving position data generated by the track sensors 156 as the first and second sample carriers 108A,B arrive at the specific blocks under the control of the segment controllers 128. The segment controllers 128 may forward the position data to the routing program 126 for updating paths and instructions for other sample carriers 108.

[0057] Reference is made to FIGS. 1 F and 1G, which illustrate an embodiment of the transport mechanisms 154 configured as linear motors. In the embodiment of FIG. 1 F, the transport mechanisms 154 include coils 178 configured to generate magnetic fields in response to signals generated by the segment controllers 128. The base 180 of the housing 168 (FIG. 1G) is magnetized so that force may be applied to the base 180 as the magnetic fields generated by the coils 178 changes. The force causes the first sample carrier 108A to move on the track 110.

[0058] The instructions from routing program 126 ultimately cause the transport mechanisms 154 to route each of the sample containers 104 to a certain set of destinations, such as different ones of the instruments 102. These routings may cause each of the sample containers 104 to visit the destinations in a particular sequence, such as visiting a centrifuge followed by visiting a decapper. The routing may require specific time windows to visit certain destinations and perform certain tests. The laboratory system 100 may have hundreds or thousands of sample carriers 108 moving simultaneously to perform a plurality of different tests on the samples (e.g., sample 164A - FIG. 1 D) contained in the sample containers 104.

[0059] Additional reference is made to FIG. 2, which is a simplified block diagram 200 illustrating an embodiment of the track 110 modeled as a plurality of adjacent blocks 160. Other modeled block representations may include many more blocks 160 or fewer blocks 160. In some embodiments, the routing program 126 or another program may electronically model the track 110 as the plurality of blocks 160. The routing program 126 then generates instructions for routing individual ones of the sample carriers 108 between adjacent ones of the blocks 160 and forwards those instructions to the appropriate segment controllers 128 for execution. For example, one or more individual segment controllers 128 may instruct specific transport mechanisms 154 to move a sample container from one block to an adjacent block when that adjacent block is vacant. One of the advantages of the block representation is that planning, executing, and monitoring movement paths for the sample carriers 108 becomes much simpler because only movement between the blocks 160 needs to be considered by individual segment controllers 128 as opposed to the routing program 126 directing every movement of every sample carrier 108 on the physical track 110.

[0060] The block diagram 200 models the physical space (where sample containers 104 or sample carriers 108 can travel) on the track 110 as the blocks 160. The embodiments herein describe moving the sample carriers 108, but these methods and apparatus may be readily configured to move the sample containers 104. Each of the blocks 160 may have a movement pattern (indicated by arrows) attached to it that indicates in which direction(s) the sample carriers 108 can move from each of the blocks 160. By default, the movement patterns may be defined by the physical layout of the track. For example, a four-way intersection having four ports may have a default movement pattern into and out of each of the four ports. The movement patterns may be physical constraints wherein portions of the track 110 corresponding to one or more of the blocks 160 may only enable the sample carriers 108 to move in specific directions. For example, the movement pattern for a particular block may be included in the associated block control program 130 for that block. In some embodiments, movement patterns may be changeable. For example, software, such as the routing program 126 and/or a block control program 130, may determine the directions of the movement patterns. These directions, for example, may limit some of the blocks to having one-way (e.g., left to right) movement patterns. Thus, the movement patterns may not be fixed.

[0061] Reference is made to certain ones of the blocks 160 that correspond to the segments 142-152 (FIG. 1 B) of the track 110. The blocks 160A-160D correspond to at least a portion of the first segment 142 (FIG. 1 B) in the physical track 110. In this example, the first segment 142 of the physical track 110 is configured to safely have four sample containers therein (with respect to collision risk) and thus has been modeled as the four blocks 160A-160D. In the example embodiment shown, each of the blocks 160A-160D is configured to have only one sample carrier therein at a time and movement of the sample carriers 108 is only from one block to an adjacent vacant block. In some embodiments, blocks may have more than one sample carrier and/or sample container therein at a time where, e.g., risk of a collision is minimal.

[0062] Additional reference is made to FIG. 3A, which illustrates an enlarged view of the first block 160A, which, in some embodiments, may be identical to the blocks 160B-160C and blocks representing other straight segments of the track 110. The block 160A has a first port 300A and a second port 300B illustrated with a doubleheaded arrow between the first port 300A and the second port 300B. The doubleheaded arrow indicates the movement pattern of the first block 160A and that the sample carriers 108 (and thus sample containers 104) are able to be received into and transported from both the first port 300A and the second port 300B.

[0063] Referring again to FIG. 2, a block 204 is a corner block corresponding to the second segment 144 of FIG. 1 B. The block 204 is configured to change the direction of sample containers 104 between the x-direction and the y-direction. Additional reference is made to FIG. 3B, which illustrates an enlarged view of the block 204. The block 204 has a first port 302A and a second port 302B illustrated with a double-headed arrow between the first port 302A and the second port 302B. The double-headed arrow indicates the movement pattern of the block 204 and that the sample carriers 108 (and thus the sample containers 104) are able to be received into and transported from both the first port 302A and the second port 302B, which causes the sample carriers 108 to change direction between the x- direction and the y-direction.

[0064] Referring again to FIG. 2, a block 206 is an intersection block corresponding to the third segment 146 of FIG. 1 B. The block 206 is configured to receive a sample carrier into a first port and transport the sample carrier out of one of two other ports. Additional reference is made to FIG. 3C, which illustrates an enlarged view of the block 206. The block 206 has a first port 304A, a second port 304B, and a third port 304C illustrated with arrows between the first port 304A, the second port 304B, and the third port 304C. The arrows indicate the movement pattern of the block 206 and that the sample carriers 108 (and thus the sample containers 104) are able to be received into one port and transported out of one of the other ports.

[0065] Other blocks shown in FIG. 2 include a block 208, which is an intersection block corresponding to the fourth segment 148 of FIG. 1 B and is configured similar to the block 206. A block 210 is a corner block corresponding to the fifth segment 150 of FIG. 1 B, and a block 212 is a comer block corresponding to the sixth segment 152 of FIG. 1 B. The block 210 and the block 212 are configured similar to the block 204. The block 210 is a mirror of block 204 and the block 212 is a mirror of block 210.

[0066] A block 214 is a four-way intersection that corresponds to the intersection segment 190 of FIG. 1A. The block 214 is configured to receive the sample carriers 108 into and transport the sample carriers 108 from first, second, third, and fourth ports. Additional reference is made to FIG. 3D, which illustrates an enlarged view of the block 214. The block 214 has a first port 306A, a second port 306B, a third port 306C, and a fourth port 306D that enable the sample carriers 108 to enter and exit all the ports.

[0067] With additional reference to FIG. 4, track 110 may alternatively be represented as a graph 400, which for the same modeling criteria may be analogous to the block diagram 200 (FIG. 2). For example, the nodes 402 (a few labelled) of the graph 400 may correspond to the blocks 160 of FIG. 2. And the edges 404 (e.g., connections) of the graph 400 are defined by the movement patterns of the blocks 160 and are illustrated as arrows. Thus, the track 110 (FIG. 1A) may be represented as a Cartesian grid of blocks and/or a graph of nodes and edges. This duality of the representations provides a flexible choice of software programming for path planning to move the sample carriers 108 (and thus the sample containers 104) on the track 110. The graph representation may be an abstraction in computer code. Many problems, such as defining a shortest path between two destinations, may be resolved using standard graph algorithms and/or programs in computer code. Therefore, once this graph representation is established for a track configuration, the graph representation may allow direct use of standard algorithms and/or programs (e.g., the Dijkstra algorithm, the A* algorithm, etc.) with known properties for path planning and/or solving various path planning problems.

[0068] Additional reference is made to FIG. 5, which illustrates another block diagram 500 wherein the blocks 502 have different movement patterns than the blocks 160 of FIG. 2. A user or the routing program 126 (FIG. 1A) may determine the movement patterns. With reference to FIG. 5, a block 504 is a straight block that only allows the sample containers 104 to move in a single direction. Additional reference is made to FIG. 6A, which illustrates an enlarged view of the block 504. The block 504 includes a first port 600A and a second port 600B, wherein the sample carriers 108 enter the first port 600A and exit the second port 600B. A block 506 is a corner block that only allows the sample carriers 108 to change direction from the x- direction to the y-direction. Additional reference is made to FIG. 6B, which illustrates an enlarged view of the block 506. The block 506 includes a first port 602A and a second port 602B, wherein the sample carriers 108 enter the first port 602A and exit the second port 602B.

[0069] A block 508 is an intersection block that only allows the sample containers 104 to enter from a first port and exit to one of two other ports. One or more switches or the like may be set to determine to which port the sample containers 104 exit. Additional reference is made to FIG. 6C, which illustrates an enlarged view of the block 508. The block 508 includes a first port 604A, which is an input port, a second port 604B, and a third port 604C. The second port 604B and the third port 604C may be output ports, wherein the sample carriers 108 enter the first port 604A and exit the second port 604B or the third port 604C. [0070] A block 510 is an intersection block that allows the sample carriers 108 to enter from a first port or a second port and exit to a third port. One or more switches or the like may be set to determine which port the sample containers 104 are allowed to enter. Additional reference is made to FIG. 6D, which illustrates an enlarged view of the block 510. The block 510 includes a first port 606A and a second port 606B, which are input ports, and a third port 606C, which is an output port. Sample carriers 108 enter one of the first port 606A or the second port 606B and exit the third port 606C. In some embodiments, the block control programs 130 may generate instructions to drive switches or the like to divert the sample carriers within the intersection blocks. The block diagram 500 may include blocks that have other movement patterns, such as block 512.

[0071] FIG. 7 illustrates a graph 700 alternatively representing track 110 analogous to the block diagram 500, wherein the nodes 702 in the graph 700 represent the blocks 502 and the edges 704 of the graph 700 are defined by the movement patterns in the block diagram 500. Thus, the track 110 (FIG. 1A) may be represented as a Cartesian grid of blocks and/or a graph of nodes and edges.

[0072] Embodiments of the diagnostic laboratory systems and routing methods described herein may use dynamic routing software to transport the sample carriers 108 between adjacent blocks 160 throughout the diagnostic laboratory systems. The routing software may be implemented by the routing program 126, for example. In some embodiments, the software architecture implemented by the routing program 126 may be divided into multiple, independently-adjustable software layers, wherein each software layer may be designed, developed, tested, and executed independently of other software layers. Use of independently-adjustable software layers enables the same architecture to be scaled and/or customized for a wide variety of laboratory system configurations.

[0073] The independently-adjustable software layers may include one or more task layers and a physical transport layer. The one or more task layers determine which ones of the instruments 102 and processes (performed by the instruments 102) are needed to complete the testing on each of the samples. The physical transport layer determines the best routes for the sample carriers 108 via the block diagrams 200/500 (FIGS. 2 and 5, respectively) or the graphs 400/700 (FIGS. 4 and 7, respectively) so that the samples are tested as determined by the one or more task layers. In such an architecture, only the physical transport layer may need to be customized to meet different laboratory system configurations.

[0074] In some embodiments, the routing program 126 is or includes a multi-layer software architecture that abstracts a logical set of tasks and/or workflow to be accomplished by a physical transport software layer. Each software layer executes independently of other software layers but may transmit data to and/or receive data from other independently executing software layers. Thus, a software layer may be changed or customized without necessarily affecting other software layers. By separating the software layers, intelligent routing can be performed to increase the efficiency of the laboratory system 100. In addition, the separation of software layers with clear interfaces allows replacing a software layer without affecting the other software layers. In some embodiments, one or more software layers may each plan/determine at least one phase (e.g., a pre- or post-process action) of a test to be performed by at least one of the instruments 102. Another software layer may determine routing of the sample containers 104 (FIG. 1 D) to the instruments 102 to perform that at least one phase. Another software layer, which may include individual block control programs 130, may generate instructions to the transport mechanisms 154 (e.g., motors, power supplies, switches, sensors, etc.) to carry out the routing of the sample containers 104.

[0075] In conventional laboratory systems, a routing program may be different for every configuration of the laboratory systems. The routing program 126 described herein may include a plurality of software layers implemented in a plurality of individually replaceable software modules as described herein that enable the routing program 126 to be easily modified to operate in other laboratory systems. Thus, unlike the routing programs used in conventional laboratory systems, the routing program 126 described herein may be used for many different laboratory configurations.

[0076] One of the technical challenges of operating diagnostic laboratory systems is achieving high throughput of samples with minimal human interaction while ensuring accuracy of tests regardless of the configuration of the laboratory systems. The routing program 126 described herein may accommodate different sizes and configurations of laboratory systems 100 without requiring a complete re-engineering of the entire routing program 126. The routing program 126 may have a plurality of software layer functions that may be constant between different laboratory system configurations. That is, the layers have been designed or programmed to operate on a plurality of laboratory system configurations.

[0077] Reference is made to FIG. 8, which illustrates an example of individual software layers 800 that may be used in the architecture of the routing program 126 in accordance with embodiments provided herein. The architecture may include other software layers, more software layers, or fewer software layers than are illustrated in FIG. 8. An order layer 802 may receive sample analysis orders and in response may identify specific tests available in laboratory system 100 to be performed on the associated samples to fulfill the sample analysis orders. In some embodiments, the order layer 802 may receive sample analysis orders from sources external to the laboratory system 100, such as a hospital information system (not shown). The order layer 802 may additionally receive sample analysis orders entered by a system operator of laboratory system 100 via the workstation 132. Based on the received inputs, the order layer 802 may generate an output (e.g., instructions) that indicates what tests are to be performed. For example, a first sample may require tests A, B, and C; a second sample may require tests X, Y, and Z; and a third sample may require only test A. Each of tests A, B, C, X, Y, and Z can be performed by one or more of the instruments 102 of the laboratory system 100. For example, the first instrument 102A may be configured to perform tests A, B, and Z and the second instrument 102B may be configured to perform tests C, X, and Y.

[0078] A task layer 804 may be configured to receive the output data generated by the order layer 802 and may generate an output (e.g., instructions) regarding the individual tasks required to perform the tests identified by the order layer 802. The task layer 804 may identify the instruments 102 that are to perform specific tests, such as tests identified in the order layer 802. For example, the task layer 804 may generate instructions indicating that the first sample (e.g., sample 164A - FIG. 1 D) needs to be aspirated and dispensed into another container and then mixed with a first reagent, while the second sample (e.g., sample 164B - FIG. 1 D) needs to be aspirated and dispensed into another container and then mixed with a second reagent, and the third sample needs to be aspirated and dispensed into another container and then mixed with a diluent. The task instructions are output from the task layer 804 and transmitted to an assignment layer 806 as input. In some embodiments, the task layer 804 may also transmit data back to the order layer 802 indicating that the task instructions have been generated. In some embodiments, the order layer 802 may delay its output until receiving data indicating that the task layer 804 is available to process additional inputs.

[0079] The assignment layer 806 may generate an output that includes specific instructions regarding the performance of the tasks in response to receiving the output generated by the task layer 804. For example, the assignment layer 806 may generate an output that assigns a first sample carrier (e.g., sample carrier 108A - FIG. 1 D) to receive the first sample container 104A containing the first sample 164A at a specific location. The assignment layer 806 may also keep track of the available number of sample carriers 108 for transporting sample containers 104 and ensure that empty sample carriers are available where they are needed by assigning those empty sample carriers to specific locations. For example, the assignment layer 806 may generate an output that assigns a specific location to receive the first sample carrier 108A with the first sample container 104A, such as the first instrument 102A, and an output that assigns the second sample carrier 108B to receive the second sample container 104B containing the second sample 164B at a specific location, such as the second instrument 102b. In the event that a test on a sample is urgent, the assignment layer 806 may generate an output assigning a high priority to the sample carrier carrying the urgent sample to allow that sample to pass other lower priority samples.

[0080] The assignment layer instructions are output from the assignment layer 806 and transmitted to a trajectory layer 808 as input. In some embodiments, the output generated by the assignment layer 806, or data indicating that the assignment layer 806 has generated an output, may also be transmitted back to the task layer 804 or other software layers 800. In some embodiments, the task layer 804 may delay its output until receiving data indicating that the assignment layer 806 is available to process additional inputs.

[0081] The trajectory layer 808 generates an output that includes specific paths for the sample carriers 108 to follow in response to receiving the output generated by the assignment layer 806. For example, the trajectory layer 808 may generate an output indicating that specific sample carriers 108 are to be transported via specific blocks 160 (FIG. 2) or specific nodes 402 (FIG. 4) to one or more locations on the track 110. The output of the trajectory layer 808 may include respective sample carrier paths that prevent the sample carriers 108 from colliding with each other. For example, the trajectory layer 808 may enable one and only one of the sample carriers 108 at a time to be located in each of the blocks 160. In addition, the trajectory layer 808 may ensure that the sample carriers 108 may not be transported from a block to a target block until the target block is vacant.

[0082] The trajectory layer 808 may also optimize paths of the sample carriers 108 such that the sample carriers 108 move to and from locations on the track 110 as efficiently as possible. In some embodiments, the trajectory layer 808 may indicate that high priority samples be moved before other samples as described above. In addition, the trajectory layer 808 may determine when the sample carriers 108 are to move from one block to an adjacent block. Also, the trajectory layer 808 may determine a schedule or time window at or within which each of the sample carriers 108 will travel to specific locations. These determinations may avoid traffic jams on the track 110.

[0083] The trajectory layer output is transmitted to a physical transport layer 810 as input. In some embodiments, the trajectory layer output, or data relating thereto, may be transmitted back to the assignment layer 806 or other software layers 800. For example, in some embodiments, the assignment layer 806 may delay its output until receiving data indicating that the trajectory layer 808 is available to process additional inputs. In addition, the assignment layer 806 may employ trajectory layer information to avoid assigning multiple sample carriers to the same locations or instruments 102 (e.g., to avoid congestion or collisions). The assignment layer 806 may thus generate more efficient assignment instructions for the sample carriers in response to receiving the trajectory instructions.

[0084] In some embodiments, the physical transport layer 810 may be implemented in the block control programs 130 (FIG. 1A) and may generate instructions that activate the transport mechanisms 154 in the track 110 to cause selected sample carriers 108 to move (e.g., through adjacent blocks 160) in response to the paths determined by the trajectory layer 808. As described previously, the transport mechanisms 154 may include and/or control track switches, motors, power supplies, power sources, sensors, transformers, and/or other electrical circuit parts. Other hardware components of the track 110 may be activated to move the sample carriers 108 pursuant to the carrier paths determined by the trajectory layer 808. For example, the physical transport layer 810 may generate instructions that cause selected switches in the intersection segments (e.g., intersection segment 146 - FIG. 1 B) to be appropriately set to form a desired sample carrier path and to cause selected sample carriers 108 to move to or from specific locations (e.g., the instruments 102). That is, the instructions from physical transport layer 810 may cause appropriate electrical signals (e.g., power/current/voltage) to be applied to components (e.g., selected motors) in the identified sample carriers 108 and/or the transport mechanisms 154 to cause the sample carriers 108 to move along the specific paths on the track 110 determined by the trajectory layer 808. In some embodiments, the physical transport layer 810 may transmit data back to the trajectory layer 808 and/or other software layers 800 indicating that the physical transport layer 810 has generated instructions. In some embodiments, physical transport layer 810, through use of block control programs 130, may ensure that only one sample container is allowed in each block 160.

[0085] In summary, each of the software layers 802, 804, 806, and 808 may be considered a “planning” layer that provides input to its next downstream software layer 800 (e.g., the order layer 802 provides input to the task layer 804, which provides input to the assignment layer 806, which provides input to the trajectory layer 808). The physical transport layer 810 may be considered an “executing” layer that puts the sample carriers 108 in motion in the laboratory system 100. For example, the transport layer 810 may translate the block instructions to physical space and all layers above the transport layer 810 may process data based on the blocks 160.

[0086] In some embodiments, each of the software layers 802, 804, 806, 808, and 810 may provide feedback up to at least its nearest upstream software layer to (a) alert the upstream software layer of its availability and (b) enable that upstream software layer, where possible, to more efficiently process inputs received from its nearest upstream software layer (e.g., the physical transport layer 810 may provide input to the trajectory layer 808 to enable the trajectory layer 808 to more efficiently process an input received from the assignment layer 806). That is, by receiving input from a downstream software layer, a software layer 800 may generate different plans and/or instructions affecting the tests to be performed by the laboratory system 100 than it would without the input from the downstream software layer. The generated alternative plans and/or instructions may, for example, avoid delays in placing the sample containers 104 in the sample carriers 108, and/or avoid traffic congestion at specific portions of the track 110 and/or the instruments 102.

[0087] Additional reference is made to FIG. 9, which illustrates an embodiment of the routing program 126 partitioned as separate and individually replaceable or configurable software modules 900, each of which respectively implements one of the software layers 800 in accordance with one or more embodiments. Thus, the software modules 900 are individual software modules. The software modules 900 may include an order manager 902 that implements the order layer 802, a task manager 904 that implements the task layer 804, an assignment planner 906 that implements the assignment layer 806, a trajectory planner 908 that implements the trajectory layer 808, and a transport driver 910 that implements the physical transport layer 810. The routing program 126 may include software modules other than the software modules 900 shown in FIG. 9. In some embodiments, communications between the software modules 900 (and thus the software layers 800) may be performed, such as via a message bus or a data-centric distributed data service (DDS). Other communications protocols may be used.

[0088] Each of the software modules 900 may reside in and be executed in a centralized fashion by one controller, such as, e.g., computer 120 (FIG. 1A). In other embodiments, the software modules 900 may be executed in one or more subprocessors of the processor 122 of the computer 120. In yet other embodiments, the software modules 900 may be executed in a distributed fashion, wherein one or more of the software modules 900 may reside in and be executed in one or more sub-controllers (each having its own memory). The software modules 900 may execute the software layers 800 independent of and/or in parallel with each other.

[0089] In some embodiments, the transport driver 910 may be implemented in the block control programs 130 (FIG. 1A) and may send electrical signals to motors, drivers, switches, and/or other hardware components of the transport mechanisms 154 to perform required motions of one or more of the sample carriers 108 pertaining to one or more first tests or phases thereof. Independently of and/or in parallel with the transport driver 910, the trajectory planner 908 may plan paths for one or more of the sample carriers 108 pertaining to one or more second tests or phases thereof so that these sample carriers 108 may reach their destinations in minimal time. Independently of and/or in parallel with the transport driver 910 and the trajectory planner 908, the assignment planner 906 may assign available sample carriers 108 to sample containers 104 pertaining to one or more third tests or phases thereof. Independently of and/or in parallel with the transport driver 910, the trajectory planner 908, and the assignment planner 906, the task manager 904 may break down one or more fourth tests into discrete tasks or phases to be performed in order to complete the one or more fourth tests. Moreover, independently of and/or in parallel with the transport driver 910, the trajectory planner 908, the assignment planner 906, and the task manager 904, the order manager 902 may process a sample analysis order into one or more fifth tests. The sample analysis order may be received, for example, from one or more users, such as doctors and other medical professionals in communication with the laboratory system 100.

[0090] As described above in connection with software layers 800, each of the software modules 902, 904, 906, and 908 may receive, in addition to inputs received from an upstream software module 900, optional inputs from one or more downstream software modules 904, 906, 908, and 910 that may be used in the execution of its respective software layer 800. In some embodiments, the inputs may include status of a software module 900 or data generated by a software module 900. For example, status or data generated by the transport driver 910 may be transmitted back to the trajectory planner 908 and/or other software modules 900. Status or data generated by the trajectory planner 908 may be transmitted back to the assignment planner 906 and/or other software modules 900. Status or data generated by the assignment planner 906 may be transmitted back to the task manager 904 and/or other software modules 900. Additionally, status or data generated by the task manager 904 may be transmitted back to the order manager 902.

[0091] Separating the routing program 126 into multiple modules/layers advantageously makes the routing program 126 more scalable, allowing small, medium, and large laboratory systems to run on the same software platform. In some embodiments, dividing the routing program 126 into multiple modules 900 and software layers 800 enables the routing program 126 to be used on a plurality of different laboratory system configurations, such as the laboratory system 100 represented in the block diagram 200 and the block diagram 500. In addition, the multiple layers in the routing program 126 may be designed, developed, and tested independently. Thus, if one of the modules 900/software layers 800 needs to be edited or replaced, the revisions may not affect the other modules 900/software layers 800. For example, if the laboratory system 100 expands to include an additional instrument that performs a similar function as existing instruments 102 (to increase sample analysis throughput), the order manager 902 and the task manager 904 may not need to be updated.

[0092] If the laboratory system 100 expands to include additional track components, the order manager 902, the task manager 904, and the assignment planner 906 may not need to be updated. The routing program 126 may update the block diagram 200 (FIG. 2) to reflect the new track configuration. For example, the routing program 126 may model track blocks as shown in the block diagram 200 based on a first configuration of the track 110 and the components of the track 110. When the configuration of the track 110 changes, the routing program 126 may update the track block model from the block diagram 200 to the block diagram 500 (FIG. 5) or another suitable block layout, for example. Such updates may be necessary when the transport mechanisms 154 and/or the track sensors 156 are updated or changed. For example, if additional transport mechanisms 154 are added to the track 110, the routing program 126 may update the relevant block model to add blocks corresponding to the additional transport mechanisms 154. The updates may also be necessary when new track segments, such as new intersections are added to and/or removed from the track 110. In some embodiments, the physical transport layer 810 and the transport driver 910 may need minor revisions because transportation of the sample carriers 108 is still based on movement of the sample carriers 108 between adjacent vacant blocks. However, other software layers 800 and modules 900 may be useable without change.

[0093] As a further example, if an electrical specification change of a hardware component of the transport system in the laboratory system 100 occurs (e.g., due to a replacement or upgrade of one of the transport mechanisms 154 and/or the track sensors 156), only the transport driver 910 may need to be updated because only the physical transport layer 810 generates instructions to activate hardware components to move the sample carriers 108 between adjacent vacant blocks. Thus, the update may correspond to updating track block assignments such as are illustrated in the block diagrams 200/500 and/or the graphs 400/700. Electrical specification changes may include, for example, changes to any hardware component’s electrical power, current, and/or voltage requirements, changes to carrier and/or track motor details affecting sample carrier acceleration and speed on track 110, updates to address timing issues related to powering up and down of hardware components, updates to address track sensor issues affecting allowable distances between moving sample carriers 108, etc.

[0094] Note that a software module 900 may be associated with more than one of the software layers 800. For example, in some embodiments, the software modules 900 may include only software modules 902 and 910, wherein order manager 902 may be associated software layers 802, 804, 806, and 808 (i.e. , the “planning” layers) while the transport driver 910 may include the physical transport layer 810 (i.e., the “executing” layer). In other embodiments, the software modules 900 may include only software modules 902, 908, and 910, wherein the software module 902 may be associated with software layers 802, 804, and 806. The trajectory planner 908 may be associated with the trajectory layer 808, and the transport driver 910 may be associated with the physical transport layer 810. In still other embodiments, the software modules 900 may include only software modules 902, 906, 908, and 910, wherein order manager 902 may be associated with the software layers 802 and 804. Other embodiments may include other software modules 900 that, e.g., may analyze test results or perform various pre- and/or post processing functions.

[0095] Returning to FIG. 2, the blocks 160 have been illustrated as being square or rectangular. Other block shapes may be used. For example, pentagonal-shaped blocks may be used to represent intersection segments having five ports. The movement of sample carriers 108 and sample containers 104 has been described as being in a two-dimensional plane. Thus, the blocks 160 have also been described as being two-dimensional. In other embodiments, movement of the sample containers 104 and/or the sample carriers 108 may be in three dimensions, such X, Y, and Z (e.g., as normal to the track 110) as described below in connection with FIG. 10. In such embodiments, one or more of the blocks 160 may be three-dimensional such as cube-shaped. [0096] Reference is made to FIG. 10, which illustrates a three-dimensional block diagram 1000 of a portion of a track (not separately shown) that may move sample carriers 108 (FIG. 1A) and/or sample containers 104 in three dimensions. That is, in some embodiments of automated diagnostic laboratory system 100, the transport system may have more than one level wherein one or more elevator-type mechanisms may move a sample carrier 108 from a block on one level to a block on another level. In the embodiment of FIG. 10, the sample carriers 108 are configured to move in an x-direction, a y-direction, and a z-direction to adjacent vacant blocks. A block 1002, e.g., has a movement pattern that limit movements to only the x- direction and the y-direction. A block 1004, e.g., has a movement pattern that limit movements to only the y-direction and the z-direction. Other blocks may have other movement patterns. The routing program 126 routes the sample carriers 108 to and from adjacent blocks or cubes as described above.

[0097] Reference is now made to FIG. 11 , which illustrates a flowchart of a method 1100 of operating a diagnostic laboratory system (e.g., laboratory system 100) for analyzing a biological sample (e.g., first sample 164A). The method 1100 includes, in block 1102, providing a track (e.g., track 110) in the diagnostic laboratory system, wherein sample containers (e.g., sample containers 104) containing biological samples are moveable on the track between a plurality of instruments (e.g., instruments 102). For example, the transport mechanisms 154 may move the sample containers 104 on the track 110. The block control programs 130 may generate signals that operate the transport mechanisms 154.

[0098] The method 1100 includes, in block 1104, modeling in software via a computer the track as a plurality of blocks (e.g., blocks 160), wherein each block includes a movement pattern that indicates in which one or more directions the sample containers may move into or out of the block. The blocks 160 may be generated or defined by a user. In other embodiments, the blocks 160 may be generated by a program in the memory 124, such as the routing program 126. Each of the blocks 160 may be as small as possible, but large enough to have an individual sample container 104 within the boundary of the block.

[0099] The method 1100 includes, in block 1106, identifying at least one test to be performed on a biological sample. For example, medical professionals may order tests to be conducted on the biological sample. In some embodiments, at least one of the order layer 802, the task layer 804, the order manager 902, or the task manager 904 may identify the at least one test.

[00100] The method 1100 includes, in block 1108, using a first software module (e.g., one of the software layers 800 or modules 900) to identify one or more instruments in the diagnostic laboratory system to perform the at least one test, the first software module being part of a program (e.g., routing program 126) comprising a plurality of individual software modules (e.g., software layers 800 or modules 900) in communication with each other. For example, one of the software layers 800 or modules 900 may identify which of the instruments 102 are to be used to perform the test. As described above, the software layers 800 and the modules 900 are in communication with each other. As a specific example, the task layer 804 and/or the task manager 904 may identify the instruments 102 that perform the at least one test based at least on data from other software layers or modules.

[00101] The method 1100 includes, in block 1110, using a second software module (e.g., one of the software layers 800 or modules 900) of the program to generate transport instructions to transport the biological sample via a sample container to the one or more instruments, wherein the transport instructions include instructions to transport the sample container between adjacent blocks. Generating transport instructions may include generating instructions to activate hardware components associated with individual blocks to move sample containers between adjacent blocks. For example, the transport driver 910 and/or the physical transport layer 810 may determine which of the blocks 160 a sample container must traverse to move to or from one of the instruments 102. As a specific example, the transport driver 910 and/or the physical transport layer 810 may determine that the first sample container 104A should travel between second block 160B and the third block 160C to move from the sample handler 102C to the first instrument 102A. The transport driver 910 and/or the physical transport layer 810 may generate instructions used by the block control programs 130 to generate signals to the transfer mechanisms 154 to cause the first sample container 104A to move from a first block to a second block upon one or more satisfactory conditions (e.g., the second block is vacant).

[00102] The method 1100, in block 1112, includes transporting the sample container to the one or more instruments in response to the transport instructions. For example, the instructions transmitted to the transfer mechanisms 154 may cause the transfer mechanisms 154 to move the first sample container 104A from one block to an adjacent vacant block in the path to a designated location for the first sample container 104A. In a more specific example, the transport driver 910 (and/or physical transport layer 810) may direct the transport mechanism 154 via an appropriate segment controller 128 (executing a block control program 130) to move the first sample container 104A from the second block 160B to the third block 160C (FIG. 1 F). The movement from the second block 160B to the third block 160C serves to transfer the first sample container 104A from the sample handler 102C to the first instrument 102A. The block control programs 130 associated with the blocks 160 ensure that only one sample container enters a vacant block 160 at a time, preventing collisions and ensuring efficient transfer of the first sample container 104A to the first instrument 102A.

[00103] Reference is now made to FIG. 12, which illustrates a flowchart of a method 1200 of operating a diagnostic laboratory system (e.g., laboratory system 100) for analyzing biological samples (e.g., first sample 164A). The method 1200 includes, in block 1202, providing a track (e.g., track 110) in the diagnostic laboratory system, wherein the biological samples are moveable on the track by way of a plurality of sample carriers (e.g., sample carriers 108).

[00104] The method 1200 includes, in block 1204, representing the track as a graph (e.g., graph 400) via a computer (e.g., computer 120), wherein the graph comprises a plurality of nodes (e.g., nodes 402) and edges (e.g., edges 404). Each node represents a segment of the track configured to have only one sample carrier therein at a time, and each edge represents a movement pattern of a sample carrier to and from nodes connected thereto. Note that the methods described above with regard to modeling the track as a plurality of blocks may be applied to representing the track as a graph.

[00105] The method 1200 includes, in block 1206, identifying at least one test to be performed on a biological sample (e.g., first sample 164A) located in a sample container (e.g., first sample container 104A) and transported via a sample carrier (e.g., first sample carrier 108A). In some embodiments, at least one of the order layer 802, the task layer 804, the order manager 902, or the task manager 904 may identify the at least one test. In some embodiments, a user or a medical professional may identify the at least one test to be performed.

[00106] The method 1200 includes, in block 1208, identifying one or more instruments (e.g., instruments 102) in the diagnostic laboratory system to perform the at least one test using a first software module (e.g., one of the software layers 800 or modules 900), the first software module being part of a program (e.g., routing program 126) comprising a plurality of individual software modules (e.g., one of the software layers 800 or modules 900) in communication with each other. For example, one of the software layers 800 or modules 900 may identify which of the instruments 102 are to be used to perform the test. As a specific example, the task layer 804 and/or the task manager 904 may identify the instruments 102 that perform the at least one test.

[00107] The method 1200 includes, in block 1210, generating transport instructions to transport the sample carrier to the one or more instruments using a second software module (e.g., one of the software layers 800 or modules 900) of the program, wherein the transport instructions include transporting the sample carrier between adjacent nodes. Generating transport instructions may include generating instructions to activate hardware components associated with individual nodes to move the biological sample between adjacent nodes. For example, the transport driver 910 and/or the physical transport layer 810 may determine which nodes 402 a sample container will traverse to move to or from one of the instruments 102. As a specific example, the transport driver 910 and/or the physical transport layer 810 may determine that the first sample container 104A should travel between certain adjacent nodes 402 to move from the sample handler 102C to the first instrument 102A. The transport driver 910 and/or the physical transport layer 810 may generate instructions used by the block control programs 130 to generate signals to the transfer mechanisms 154 to cause the first sample container 104A to move between the certain adjacent nodes 402.

[00108] The method 1200 includes, in block 1212, transporting the sample carrier to the one or more instruments in response to the transport instructions. For example, the instructions transmitted to the transfer mechanisms 154 may cause the first sample carrier 108A to move to adjacent vacant nodes in order to move the first sample container 104A to a designated location. In a more specific example, the transport driver 910 (and/or physical transport layer 810) may direct the transport mechanism 154 via an appropriate segment controller 128 (executing a block control program 130) to move the first sample container 104A between adjacent nodes, which serves to transfer the first sample container 104A from the sample handler 102C to the first instrument 102A. The block control programs 130 associated with the nodes 402 ensure that only one sample container enters a vacant node 402 at a time, preventing collisions and ensuring efficient transfer of the first sample carrier 108A to the first instrument 102A.

[00109] While the disclosure is susceptible to various modifications and alternative forms, specific method and apparatus embodiments have been shown by way of example in the drawings and are described in detail herein. It should be understood, however, that the particular methods and apparatus disclosed herein are not intended to limit the disclosure.

Claims

WHAT IS CLAIMED IS:

1. A method of operating a diagnostic laboratory system for analyzing a biological sample, comprising: providing a track in the diagnostic laboratory system, wherein sample containers containing biological samples are moveable on the track between a plurality of instruments; modeling in software via a computer the track as a plurality of blocks, wherein each block includes a movement pattern that indicates in which one or more directions the sample containers move into or out of the block; identifying at least one test to be performed on a biological sample; using a first software module to identify one or more instruments in the diagnostic laboratory system to perform the at least one test, the first software module being part of a program comprising a plurality of individual software modules in communication with each other; using a second software module of the program to generate transport instructions to transport the biological sample via a sample container to the one or more instruments, wherein the transport instructions include instructions to transport the sample container through adjacent blocks; and transporting the sample container to the one or more instruments in response to the transport instructions.

2. The method of claim 1 , wherein one or more of the blocks comprise a first port and a second port, and wherein the transport instructions allow sample containers to enter and exit both the first port and the second port.

3. The method of claim 1 , wherein one or more of the blocks comprise a first port and a second port, and wherein the transport instructions allow sample containers to enter the first port and exit the second port.

4. The method of claim 1 , wherein one or more of the blocks is an intersection block comprising a first port, a second port, and a third port, and wherein the transport instructions allow sample containers to enter and exit the first port, the second port, and the third port.

5. The method of claim 1 , wherein one or more of the blocks is an intersection block comprising a first port, a second port, and a third port, and wherein the transport instructions allow sample containers to enter the first port and exit one of the second port or the third port.

6. The method of claim 1 , wherein generating transport instructions comprises generating instructions using the second software module to apply appropriate electrical power to a selected one or more sample carriers, track segments, or track switches of the track to move the sample container on the track.

7. The method of claim 1 , wherein generating transport instructions comprises generating instructions to cause a sample carrier to receive the sample container containing the biological sample at a specific location on the track.

8. The method of claim 1 , further comprising, after the modeling, changing the movement pattern associated with some of the blocks.

9. The method of claim 1 , wherein generating transport instructions comprises generating instructions to activate hardware components associated with individual blocks to move sample containers from one block to an adjacent block.

10. The method of claim 1 , wherein one or more of the blocks is an intersection block configured to have therein only one sample container at a time.

11 . The method of claim 1 , wherein each of the blocks is configured to have therein only one sample container at a time.

12. The method of claim 1 , wherein each of the blocks corresponds to a track portion sized to have at least one sample carrier within the track portion’s boundary.

13. A method of operating a diagnostic laboratory system for analyzing biological samples, comprising: providing a track in the diagnostic laboratory system, wherein the biological samples are moveable on the track by way of a plurality of sample carriers; representing the track as a graph via a computer, the graph comprising a plurality of nodes and edges, wherein each node represents a portion of the track configured to have only one sample carrier therein at a time and wherein each edge represents a movement pattern of a sample carrier to and from nodes connected thereto; identifying at least one test to be performed on a biological sample located in a sample container and transported via a sample carrier; identifying one or more instruments in the diagnostic laboratory system to perform the at least one test using a first software module, the first software module being part of a program comprising a plurality of individual software modules in communication with each other; generating transport instructions to transport the sample carrier to the one or more instruments using a second software module of the program, wherein the transport instructions include transporting the sample carrier between adjacent nodes; and transporting the sample carrier to the one or more instruments in response to the transport instructions.

14. The method of claim 13, wherein at least one of the plurality of nodes represents a track portion comprising a three-way or four-way track intersection.

15. The method of claim 13, wherein the generating transport instructions comprises generating instructions using the second software module to apply appropriate electrical power to a selected one or more sample carriers or transfer mechanisms of the track to move the sample container on the track.

16. The method of claim 13, wherein the generating transport instructions comprises generating instructions to activate hardware components associated with individual nodes to move the biological sample between adjacent nodes.

17. A diagnostic laboratory system for analyzing a biological sample, comprising: at least one instrument for preparing or testing the biological sample; a track configured to transport a sample container to and from the at least one instrument, wherein the sample container is configured to contain therein the biological sample to be analyzed; and a computer configured to: model in software the track as a plurality of blocks, wherein each of the blocks includes a movement pattern that indicates in which one or more directions the sample container moves into or out of the block; identify at least one test to be performed on a biological sample by at least one instrument; and execute a program to control operation of the diagnostic laboratory system, the program having an architecture comprising a plurality of individual software modules in communication with each other, the plurality of individual software modules including: a first software module to identify one or more instruments in the diagnostic laboratory system to perform the at least one test, and a second software module to generate transport instructions to transport the biological sample to the one or more instruments, wherein the transport instructions include instructions to transport the biological sample from one block to an adjacent block.

18. The diagnostic laboratory system of claim 17, wherein at least one movement pattern indicates one or more directions that the sample container is configured to move through a block modeling a three-way or four-way track intersection.

19. The diagnostic laboratory system of claim 17, wherein the transport instructions are configured to activate hardware components associated with individual ones of the blocks to move the sample container from one block to an adjacent block.

20. The diagnostic laboratory system of claim 17, wherein each of the blocks is configured to have only one sample container therein at a time.