Systems and methods for detecting fallen containers suitable for apparatus for automated evaluation of microorganism growth in test samples

Patent metadata

Field	Value
Publication number	US-9470510-B2
Application number	US-201313796874-A
Country	US
Kind code	B2
Filing date	Mar 12, 2013
Priority date	Mar 29, 2012
Publication date	Oct 18, 2016
Grant date	Oct 18, 2016

Abstract

Methods, systems, computer program products, apparatus and circuits are configured to detect fallen containers upstream or proximate an intake zone suitable for automated evaluation apparatus using different sensors, including at least one lower sensor and at least one upper sensor which is positioned to project an optical signal at a height corresponding to a top portion of an upright container to thereby allow an increased reliability in detection of different orientations and positions of fallen containers. An optional second lower sensor may be used which is longitudinally spaced apart from the first lower sensor and the lower sensors can transmit optical signals across the container travel path that do not intersect.

First claim

That which is claimed:

1. An automated misfeed and/or fallen container detection system comprising:
a conveyor providing a travel path for groups of elongated containers;
a rotating wheel in cooperating alignment with the conveyor, the wheel having a plurality of circumferentially spaced apart pockets, each pocket configured to accept a single upright elongated container;
a plurality of spaced apart sensors including (i) at least one lower sensor configured to transmit a respective optical signal across the container travel path proximate the wheel at a height that is less than a width dimension of the containers, the at least one lower sensor including a first lower sensor that transmits a respective first optical signal across a front edge portion of a pocket of the wheel facing the conveyor at a loading position and (ii) at least one upper sensor that is positioned proximate the wheel configured to transmit an optical signal at a height corresponding to a top portion of an upright container to thereby allow detection of different orientations and positions of fallen containers and/or container jam or blockage conditions;
a pair of laterally spaced apart sidewalls facing each other across the conveyor, wherein the sidewalls have a parallel segment that merges into a curved segment where the sidewalls travel toward each other proximate the rotating wheel to have a width that is more narrow proximate the wheel than along the parallel segment, wherein the first lower sensor is held outside the curved segment of one of the sidewalls; and
a bridge member that extends across and above the curved segment of the sidewalls held by the housing, wherein the at least one upper sensor is held by the bridge member.

2. The system of claim 1 , wherein the at least one lower sensor comprises a first lower sensor and a second lower sensor, the second lower sensor positioned longitudinally spaced apart from the first lower sensor, the first lower sensor being downstream of the second lower sensor, with each residing proximate the rotating wheel, wherein the first and second lower sensors are configured to transmit respective first and second non-intersecting first and second optical signals across the conveyor container travel path proximate the rotating wheel at a height that is no greater than 1-2 inches associated with a width dimension of the containers.

3. The system of claim 2 , wherein the second lower sensor is a retroreflective sensor, and wherein the second optical signal crosses the conveyor travel path a distance “D” away from the first optical signal, and wherein the distance D is greater than one diameter corresponding to between 1-2 inches but less than two diameters corresponding to between 2-4 inches of the elongated containers transported by the conveyor.

4. The system of claim 2 , wherein the travel path narrows in width between the sidewalls as it approaches the wheel to a width that is less than eight inches corresponding to a width that is less than four container diameters of containers having diameters between 1-2 inches, and wherein the system comprises a control circuit that is configured to identify a bridge of frictionally engaged upright containers based on data from at least the second lower sensor, then automatically reverse direction of the conveyor to dislodge the bridge.

5. The system of claim 1 , further comprising a plurality of elongated containers on the conveyor, wherein the containers are optically transmissive tubes with a top cap, and the containers have one size with an outer diameter, wherein the at least one lower sensor is positioned to transmit a respective optical signal at a height that is no greater than 1-2 inches corresponding to the diameter of the containers.

6. The system of claim 2 , wherein the first and second lower sensors have optical signals that diverge away from each other as they project across the conveyor so that the first and second optical signals are closer together on one side of the conveyor travel path relative to an opposing side of the travel path.

7. The system of claim 1 , further comprising a control circuit that is configured to direct the wheel to rotate a defined distance then stop to receive a container from a container queue on the conveyor, and wherein the control circuit is configured to rotate the wheel when data from the at least one upper sensor confirms an upright container is in position in a receiving pocket of the wheel.

8. The system of claim 1 , further comprising a control circuit that is configured to direct the conveyor to reverse direction when a fault condition is identified based on data from at least one of the at least one lower sensor.

9. The system of claim 1 , further comprising a control circuit that is configured to direct the wheel to rotate with an empty receiving pocket to an indexed position when a fault condition associated with a fallen container is identified as located away from the receiving pocket based on data from the at least one lower sensor and the at least one upper sensor.

10. The system of claim 1 , further comprising a control circuit that is configured to detect multiple different fault conditions associated with fallen containers adjacent or in the wheel and (i) direct the wheel to rotate a defined distance then stop to receive a container from a container queue on the conveyor, (ii) direct the wheel to rotate when data from the at least one upper sensor confirms an upright container is in position in a receiving pocket of the wheel, (iii) direct the conveyor to reverse direction when a fault condition is identified based on data from the at least one lower sensor, and (iv) direct the wheel to rotate with an empty receiving pocket to an indexed position when a fault condition associated with a fallen container is identified as located away from the receiving pocket based on data from the at least one lower sensor and the at least one upper sensor.

11. The system of claim 1 , wherein the travel path between the sidewalls narrows in width as it approaches the wheel, wherein the curved segment of at least one of the sidewalls is concave proximate an outer perimeter of the wheel, and wherein the at least one lower sensor comprises a retroreflective sensor that transmits a respective optical signal through a front edge portion of the receiving pocket.

12. The system of claim 1 , further comprising a plurality of containers on the conveyor, wherein the containers are optically transmissive tubes with a top cap holding biospecimens, wherein the first lower sensor is positioned to transmit the first optical signal at a height that is less than 1-2 inches so as to be no greater than an outer diameter of the containers.

13. The system of claim 12 , wherein at least some of the containers comprise blood samples.

14. The system of claim 1 , further comprising a control circuit that is configured to monitor the at least one upper sensor for a short interval after a fallen container fault is identified based on data from at least one of the at least one lower sensor to assess whether a container enters a receiving pocket of the wheel before generating a fallen container notification.

15. An automated detection apparatus for detection of microorganism growth in test samples, comprising:
a housing enclosing an interior temperature controlled chamber;
a container loading system comprising a conveyor defining a travel path that transports groups of elongated containers with test samples to the housing for processing;
a rotating wheel in cooperating alignment with the conveyor, the wheel having a plurality of circumferentially spaced apart po

Assignees

• Bio Merieux Inc

Inventors

• Wilson Mark S
• Knebel James
• Vivet Thierry

Classifications

• B65G47/846 Primary

  Star-shaped wheels or wheels equipped with article-engaging elements · CPC title

• G01N2035/00643

  detecting malfunctions in conveying systems · CPC title

• G01N35/00623

  of instruments · CPC title

• B65G2203/044

  Optical · CPC title

• G01N35/00603

  Reinspection of samples · CPC title