Laboratory automated instruments, systems, and methods

Abstract

A laboratory automated system can include a host conveyor assembly configured to transport a plurality of carriers and receptacles coupled thereto between at least a sample processing instrument and at least one assay instrument. The system includes an intermediate conveyor assembly configured to transport a plurality of carriers and receptacles coupled thereto from within sample processing instrument to the host conveyor assembly. The system also includes an intermediate conveyor assembly for each assay instrument configured to transport a plurality of carriers from host conveyor assembly to a respective processing position within the assay instrument. The intermediate conveyor assembly coupled to the assay instrument can include a buffer conveyor subassembly configured to receive carriers from the host conveyor assembly, and a spur conveyor assembly configured to transport a carrier to the processing position of the assay instrument.

1 . An automated sample processing system comprising:
 a first instrument comprising a first automated pipettor configured to aspirate at least a portion of a sample from a first sample containing receptacle and dispense the portion of the first sample into a first processing receptacle;   a second instrument comprising a second automated pipettor configured to aspirate at least portions of samples from processing receptacles containing samples at a first processing position within the second instrument and dispense at least portions of samples into assay receptacles, the second instrument being further configured to perform first assays on the portions of the samples contained within assay receptacles;   a first conveyor assembly configured to transport a first carrier coupled to the first processing receptacle containing the portion of the first sample dispensed by the first automated pipettor from the first instrument to a position outside the first instrument;   a second conveyor assembly configured to receive the first carrier coupled to the first processing receptacle from the first conveyor assembly at the position outside the first instrument, and to transport the first carrier to a first position outside the second instrument;   a third conveyor assembly configured to
 (i) receive the first carrier from the second conveyor assembly at the first position outside the second instrument, 
 (ii) transport the first carrier to the first processing position within the second instrument at which the second automated pipettor of the second instrument aspirates at least a portion of the first sample from the first processing receptacle for subsequently dispensing the portion of the first sample into an assay receptacle, 
 (iii) after the second automated pipettor of the second instrument aspirates at least a portion of the first sample from the first processing receptacle, transport the first carrier coupled to the first processing receptacle from the first processing position to a second position outside the second instrument, and 
 (iv) transfer the first carrier at the second position outside the second instrument to the second conveyor assembly. 
   
     
     
         2 . The automated sample processing system of  claim 1 , wherein the second instrument is configured to perform first assays by subjecting samples contained within assay receptacles to nucleic acid amplification reaction conditions. 
     
     
         3 . The automated sample processing system of  claim 1 , wherein the first instrument is further configured to (a) couple the first processing receptacle with the first carrier, or (b) decap and cap at least one of the first sample containing receptacle and the first processing receptacle. 
     
     
         4 . The automated sample processing system of  claim 1 , wherein the first instrument further comprises (a) an input bay configured to manually receive the first sample containing receptacle, or (b) an input bay configured to automatically receive the first sample containing receptacle. 
     
     
         5 . (canceled) 
     
     
         6 . The automated sample processing system of  claim 1 , further comprising a third instrument comprising a third automated pipettor configured to aspirate at least portions of samples from processing receptacles containing samples at a second processing position within the third instrument and dispense the portions of samples into second assay receptacles, the third instrument being further configured to perform second assays on samples contained within assay receptacles. 
     
     
         7 . The automated sample processing system of  claim 6 , wherein the first assays are different than the second assays. 
     
     
         8 . The automated sample processing system of  claim 6 , wherein:
 the third instrument is configured to perform the second assays by subjecting samples contained within assay receptacles to nucleic acid amplification reaction conditions;   the second instrument is configured to perform first assays by subjecting samples contained within assay receptacles to nucleic acid amplification reaction conditions, the subjecting samples contained within assay receptacles to nucleic acid amplification reaction conditions of the first assay comprises adding a first reagent to samples contained within assay receptacles; and   the subjecting samples contained within assay receptacles to nucleic acid amplification reaction conditions of the second assay comprises adding a second reagent, different than the first reagent, to samples contained within assay receptacles.   
     
     
         9 . (canceled) 
     
     
         10 . The automated sample processing system of  claim 6 , wherein the first assays are configured to determine the presence of a first analyte, and wherein the second assays are configured to determine the presence of a second analyte different than the first analyte. 
     
     
         11 . The automated sample processing system of  claim 6 , wherein the first assays are the same as the second assays. 
     
     
         12 . The automated sample processing system of  claim 6 , further comprising a fourth conveyor assembly configured to
 (i) receive a second carrier coupled to a second processing receptacle from the second conveyor assembly at a first position outside the third instrument,   (ii) transport the second carrier to the second processing position within the third instrument at which the third automated pipettor of the third instrument aspirates at least a portion of a second sample from the second processing receptacle for subsequently dispensing the portion of the second sample into a second assay receptacle, and   (iii) after the third automated pipettor of the third instrument aspirates the portion of the second sample from the second processing receptacle, transport the second carrier from the second processing position to a second position outside the third instrument;   wherein the first automated pipettor of the first instrument is further configured to aspirate at least a portion of the second sample from the second sample containing receptacle and dispense the portion of the second sample into the second processing receptacle;   wherein the first conveyor assembly is further configured to transport the second carrier coupled to the second processing receptacle containing the portion of the second sample dispensed by the first automated pipettor from the first instrument to the position outside the first instrument; and   wherein the second conveyor assembly is further configured to receive the second carrier coupled to the second processing receptacle from the first conveyor assembly at the position outside the first instrument, and transport the second carrier to the first position outside the third instrument.   
     
     
         13 . The automated sample processing system of  claim 12 , wherein the first instrument comprises a writer configured to transfer a first identifier to at least one of the first carrier and the first processing receptacle, and to transfer a second identifier to at least one of the second carrier and the second processing receptacle. 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . The automated sample processing system of  claim 13 , wherein:
 the writer is configured to transfer the first identifier to the first carrier and the second identifier to the second carrier;   the first carrier comprises a first RFID tag;   the second carrier comprises a second RFID tag; and   the writer comprises an RFID writer configured to transmit the first identifier to the first RFID tag and the second identifier to the second RFID tag.   
     
     
         17 . The automated sample processing system of  claim 13 , wherein:
 the writer is configured to transfer the first identifier to the first carrier and the second identifier to the second carrier;   the second conveyor system comprises:
 a first portion configured to transport carriers from the position outside the first instrument to the first position outside the second instrument; 
 a second portion configured to transport carriers from the first position outside the second instrument to the second position outside the second instrument; and 
 a diverter configured to transfer the first carrier from the first portion of the second conveyor assembly to the third conveyor assembly based on the first identifier, and configured to transfer the second carrier from the first portion of the second conveyor assembly to the second portion of the second conveyor assembly based on the second identifier; 
   the automated sample processing system further comprises a control system configured to transmit a control signal to the diverter;   the diverter is configured to transfer the first carrier from the first portion of the second conveyor assembly to the third conveyor assembly based on the control signal, and configured to transfer the second carrier from the first portion of the second conveyor assembly to the second portion of the second conveyor assembly based on the control signal;   the second conveyor assembly further comprises a sensor configured to detect the first identifier of the first carrier and the second identifier of the second carrier, and to transmit a sensor signal to the control system based on the detected first identifier and the detected second identifier; and   the control system is configured to adjust the control signal transmitted to the diverter based on the sensor signal received from the sensor.   
     
     
         18 . (canceled) 
     
     
         19 . The automated sample processing system of  claim 17 , wherein the sensor of the second conveyor assembly comprises an RFID antenna or an image sensor. 
     
     
         20 . (canceled) 
     
     
         21 . The automated sample processing system  claim 13 , wherein:
 the writer is configured to transfer the first identifier to the first carrier and the second identifier to the second carrier; and   the third conveyor assembly comprises a sensor configured to detect the first identifier of the first carrier positioned at the first processing position; and   the second instrument is configured to start aspirating the portion of the first sample from the first processing receptacle containing the portion of the first sample at the first processing position within the second instrument based on the detected first identifier.   
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . The automated sample processing system of  claim 13 , wherein:
 the writer is configured to transfer the first identifier to the first carrier and the second identifier to the second carrier;   the second conveyor system further comprises:
 a first portion configured to transport carriers from the second position outside the second instrument to the first position outside the third instrument; 
 a second portion configured to transport carriers from the first position outside the third instrument to the second position outside the third instrument; and 
 a diverter configured to transfer the second carrier from the first portion of the second conveyor assembly to the fourth conveyor assembly based on the second identifier of the second carrier, and configured to transfer the first carrier from the first portion of the second conveyor assembly to the second portion of the second conveyor assembly based on the first identifier; 
   the automated sample processing system further comprises a control system configured to transmit a control signal to the diverter;   the diverter is configured to transfer the second carrier from the first portion of the second conveyor assembly to the fourth conveyor assembly based on the control signal, and configured to transfer the first carrier from the first portion of the second conveyor assembly to the second portion of the second conveyor assembly based on the control signal;   the second conveyor assembly further comprises a sensor configured to detect the first identifier of the first carrier and the second identifier of the second carrier, and to transmit a second sensor signal to the control system based on the detected first identifier and the detected second identifier; and   the control system is configured to adjust the control signal transmitted to the diverter based on the second sensor signal received from the sensor of the second conveyor assembly.   
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . The automated sample processing system of  claim 13 , wherein:
 the fourth conveyor assembly comprises a sensor configured to detect the second identifier of the second carrier positioned at the second processing position; and   the third instrument is configured to start aspirating the portion of the second sample from the second processing receptacle containing the second sample at the second processing position within the third instrument based on the detected second identifier.   
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . (canceled) 
     
     
         32 . The automated sample processing system of  claim 1 , wherein the third conveyor assembly comprises:
 a first conveyor subassembly comprising an input portion configured to transport the first carrier from the second conveyor assembly to a first transfer position, and an output portion configured to transport the first carrier from a second transfer position to the second position outside the second instrument; and   a second conveyor subassembly configured to transport the first carrier between a third transfer position and the first processing position within the instrument, and   a diverter configured to transport the first carrier from the first transfer position to the third transfer position while simultaneously transporting another carrier from the third transfer position to the second transfer position.   
     
     
         33 . The automated sample processing system of  claim 32 , wherein the second conveyor subassembly comprises (a) a gripper configured to secure the first carrier to the first processing receptacle as a distal end of the second automated pipettor is withdrawn from the first processing receptacle, or (b) a movable track configured to transport the first carrier between the third transfer position and the first processing position within the instrument. 
     
     
         34 . (canceled) 
     
     
         35 . The automated sample processing system of  claim 1 , wherein the first carrier comprises a puck. 
     
     
         36 . The automated sample processing system of  claim 1 , wherein:
 the first instrument further comprises a first housing;   the first automated pipettor is positioned in the first housing;   the second instrument further comprises a second housing; and   the second automated pipettor is positioned in the second housing.   
     
     
         37 . (canceled) 
     
     
         38 . (canceled) 
     
     
         39 . An automated sample processing system comprising:
 a first conveyor assembly configured to transport a first carrier coupled to a first processing receptacle containing a first sample, and a second carrier coupled to a second processing receptacle containing a second sample;   a second conveyor assembly configured to   (i) receive the first carrier from the first conveyor assembly;   (ii) transport the first carrier to a first processing position; and   (iii) return the first carrier to the first conveyor assembly;   a first instrument comprising a first automated pipettor configured to aspirate at least a portion of the first sample from the first processing receptacle at the first processing position and dispense the portion of the first sample into a first assay receptacle, wherein the first processing position is within the first instrument, and wherein the first instrument is further configured to perform a first assay on the first sample contained within the first assay receptacle to determine the presence of a first analyte in the first sample;   a third conveyor assembly configured to   (i) receive the second carrier from the first conveyor assembly;   (ii) transport the second carrier to a second processing position; and   (iii) return the second carrier to the first conveyor assembly; and   a second instrument comprising a second automated pipettor configured to aspirate at least a portion of the second sample from the second processing receptacle at the second processing position and dispense the portion of the second sample into a second assay receptacle, wherein the second processing position is within the second instrument, and wherein the second instrument is further configured to perform a second assay on the second sample contained within the second assay receptacle to determine the presence of a second analyte in the second sample.   
     
     
         40 . The automated sample processing system of  claim 39 , wherein the first assay comprises subjecting the first sample contained within the first assay receptacle to nucleic acid amplification reaction conditions. 
     
     
         41 . The automated sample processing system of  claim 39 , wherein the first assay is different than the second assay. 
     
     
         42 . The automated sample processing system of  claim 39 , wherein the second assay comprises subjecting the second sample contained within the second assay receptacle to nucleic acid amplification reaction conditions. 
     
     
         43 . The automated sample processing system of  claim 39 , wherein the first analyte and the second analyte are the same analytes. 
     
     
         44 . The automated sample processing system of  claim 39 , wherein the first analyte and the second analyte are different analytes. 
     
     
         45 . The automated sample processing system of  claim 39 , wherein:
 at least one of the first processing receptacle and the first carrier comprises a first identifier;   at least one of the second processing receptacle and the second carrier comprises a second identifier; and   the first conveyor system comprises:   a first portion configured to transport the first carrier and the second carrier to a first position upstream from the second conveyor system;   a second portion configured to transport the first carrier and the second carrier to a second position upstream from the third conveyor system; and   a first diverter configured to transfer the first carrier from the first portion of the first conveyor assembly to the second conveyor assembly based on the first identifier, and configured to transfer the second carrier from the first portion of the first conveyor assembly to the second portion of the first conveyor assembly based on the second identifier.   
     
     
         46 . The automated sample processing system of  claim 45 , further comprising a control system configured to transmit a first control signal to the first diverter;
 wherein the first diverter is configured to transfer the first carrier from the first portion of the first conveyor assembly to the second conveyor assembly based on the first control signal, and configured to transfer the second carrier from the first portion of the first conveyor assembly to the second portion of the first conveyor assembly based on the first control signal;   wherein the first conveyor assembly further comprises:
 a first sensor configured to (i) detect the first identifier when the first carrier is at the first position upstream from the second conveyor system, (ii) detect the second identifier when the second carrier is at the first position upstream from the second conveyor system, and (iii) transmit a first sensor signal to the control system based on the detected first identifier and the detected second identifier; 
 a second sensor configured to (i) detect the first identifier when the first carrier is at the second position upstream from the third conveyor system, (ii) detect the second identifier when the second carrier is at the second position upstream from the third conveyor system, and (iii) transmit a second sensor signal to the control system based on the detected first identifier and the detected second identifier; 
 a third portion configured to transport the first carrier and the second carrier to a third position downstream from the second instrument; and 
 a second diverter configured to
 transfer the first carrier from the second portion of the first conveyor assembly to the third portion of the first conveyor assembly based on the first identifier; 
 transfer the second carrier from the second portion of the first conveyor assembly to the third conveyor assembly based on the second identifier; 
 transfer the second carrier from the second portion of the first conveyor assembly to the third conveyor assembly based on the second control signal; and 
 transfer the first carrier from the second portion of the first conveyor assembly to the third portion of the first conveyor assembly based on the second control signal; and 
 
   wherein the control system is configured to
 adjust the first control signal transmitted to the first diverter based on the first sensor signal received from the first sensor; 
 transmit a second control signal to the second diverter; and 
 adjust the second control signal transmitted to the second diverter based on the second sensor signal received from the second sensor. 
   
     
     
         47 . (canceled) 
     
     
         48 . (canceled) 
     
     
         49 . The automated sample processing system  claim 46 , wherein:
 the second conveyor assembly further comprises a third sensor configured to detect the first identifier of the first carrier positioned at the first processing position;   the first instrument is configured to start aspirating the portion of the first sample from the first processing receptacle at the first processing position based on the detected first identifier;   the third conveyor assembly further comprises a fourth sensor configured to detect the second identifier of the second carrier positioned at the second processing position; and   the second instrument is configured to start aspirating the portion of the second sample from the second processing receptacle at the second processing position based on the detected second identifier.   
     
     
         50 - 175 . (canceled)