CONTROL & AUTOMATION AN ADVANCED SETUP
MITSUBISHI ELECTRIC
Formulating innovation in chemical handling
Mitsubishi Electric has helped Labman Automation in the development of a compact , fully automated and highthroughput formulation system in under seven months . The innovative unit has been created for CPI ’ s National Formulation Centre and is built around two MELFA RV-series six-axis robots with CR800 controllers . These support processing , dispensing and handling activities for a wide range of materials . This advanced setup can enhance productivity by 5-10 times , improving CPI ’ s offering to companies bringing advanced paint , coating and battery formulations to the market .
CPI is a leading independent technology and innovation centre that connects academia , businesses , government and investors with the aim to bring innovative ideas and research to the marketplace . Its Sedgefield-based National Formulation Centre provides the tools and expertise to support companies in the commercialisation of their next-generation formulations for active pharmaceutical ingredients , paints , coatings , detergents and batteries .
As part of its continuous programme of investment in new equipment and technologies , CPI decided to develop a selfcontained , universal automatic formulation system with a glovebox enclosure that could address even the most ambitious processing needs . This would support the commercialisation of new formulations in a variety of markets and applications .
CREATING A FLEXIBLE PROCESSING SETUP
To develop the new formulation system , CPI contacted its preferred specialist in lab automation and robotics , Labman . Dr . Lynn Donlon , Principal Scientist at CPI , explains : “ Labman is a trusted partner for developing customised automation systems . We have collaborated with them on a number of projects across various applications and they have always delivered excellent solutions .”
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
The innovative formulation system is built around two MELFA RV series six-axis robots that support processing , dispensing and handling activities for a wide range of materials .
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 multifunction probe station module . Samples can also be transferred to syringes to prepare coatings on a separate , CPI / Labmandesigned 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 high-speed 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 .”
54 PECM Issue 53