For this project , the two companies designed a compact , modular work cell that could fit three processing sections in an area of only 21 m2 . In effect , the system can conduct processing , dispensing and measurements , as well as safe handling of volatile components , nanomaterials and other hazardous substances .
In the first module , sample pots are loaded at high speed and moved to the dispensing unit after their lids have been removed . There , dispensers for solid , liquid and slurry applications quickly fill the pots with accuracies of ± 1mg , ± 10mg and ± 25mg , respectively . The containers are then automatically moved to the processing section and loaded into a dual asymmetrical centrifuge that mixes their contents . At this stage , a pendant drop module can measure the surface tension of the formulations and perform spectral analyses using a multi-function probe station module . Samples can also be transferred to syringes to prepare coatings on a separate , CPI / Labman-designed platform . The final module handles hazardous components by utilising powder feeders for nanoparticles and can also add a range of liquids and solvents to the formulations .
Robotising the unit Six-axis robots increase the throughput of the system by both handling samples quickly and by supporting continuous operations , processing out of hours and during weekends . They perform key activities , such as removing or applying lids and caps , in the processing and glovebox units . It is important that these tasks are carried out reliably at highspeed and with high accuracy using robots that offer payloads and reach to fit the design of the setup .
For this project , CPI requested a quick delivery and installation of the robots so that the system could be developed , installed and made operational as quickly as possible . To address these aspects , Labman contacted Mitsubishi Electric . Anthony Cumpson , Senior Engineer at Labman , comments : “ We selected the MELFA RV series six-axis industrial robots as we knew that they could provide the performance required . Also , the responsiveness of Mitsubishi Electric ’ s team and the company ’ s ability to promptly deliver the equipment , were crucial for the quick turnaround of this project .” Furthermore , the six axes utilised make it easier to reach diagonally into key components , such as mixers .
Dr . Lynn Donlon adds : “ We are extremely happy with the RV robots . They are perfectly suited for performing the delicate operations within the unit , such as loading and unloading of pots and powder dispense units .”
The project was further streamlined thanks to the compact CR800 robot controllers , which are easy to program and wire . These also enable CPI to implement any basic changes without requiring advanced programming skills .
To optimise space utilisation and reduce the overall footprint of the system , particularly in the glovebox section , Mitsubishi Electric and Labman developed customised solutions that allowed the robots to pick the necessary equipment while moving within set limits . Placing the robotic arms on tracks , for example , was particularly beneficial to making the most of the room available . Such tracks use a Mitsubishi Electric HG-SR52B motor and is linked to the CR800 controllers for accurate positioning .
The RV series also supports the creation of robot safety zones to enable cooperative applications . Human operators can access one of the three sections , stopping any automated activity there , while the other two can continue their tasks without interruptions .
Ready , set , formulate !
The entire system was built in under seven months , half of the time that is typically required for similar projects . Since starting operations , the formulation unit has been widely utilised by CPI and its partners , raising considerable interest from specialists in different sectors . In effect , the solution can increase productivity by 5-10 times compared to conventional operations .
In addition , the flexible and modular build has been designed to support further expansions . Dr . Lynn Donlon explains : “ We are extremely happy with the solution that has been developed and technical support provided by both Labman and Mitsubishi Electric . Since building this formulation system we have expanded the scope of our collaboration by adding further modules to the unit . We are working on plans to develop the capabilities of the system even further in the near future .”
Ian Patterson , Key Account Manager at Mitsubishi Electric , concludes : “ It is great to see our robots used in such an innovative application , supporting next-generation formulations . We ’ ve had brilliant feedback and look forward to continuing our work with Labman and CPI .”
gb3a . mitsubishielectric . com
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