Summary: DSI Innovations delivered a robotic kit assembly and vision inspection system for a leading life sciences manufacturer. The custom solution improved accuracy, efficiency, and safety by automating test kit assembly with a SCARA robot, multi-camera vision system, and touchscreen interface—reducing manual labor and preparing the line for scalable production.
Client Challenge
A life sciences manufacturer faced challenges in their manual test kit assembly process, which was labor-intensive and prone to errors such as incorrect or missing components. The repetitive nature of the task placed a burden on employees, reducing efficiency and increasing the risk of quality issues.
To address these issues, our client needed an automated solution that could:
- Assemble test kits with 8 different-sized components accurately and efficiently.
- Verify each kit component using a vision system to ensure correctness.
- Reduce operator fatigue while improving production consistency.
Our Solution
Our team designed, developed, and deployed a robotic kit assembly cell featuring a SCARA robot with a camera-based vision inspection system to automate the assembly process and improve accuracy. The key components and features of the solution included:
Cell Enclosure and Guarding:
- Our team built an extruded aluminum structure with clear polycarbonate walls to ensure safety.
- We installed dual-channel safety switches on access doors to disable the robot when opened, meeting safety best practices and standards and preventing accidental operator injury.
Epson SCARA Robot with Electric Gripper:
- A 4-axis Epson LS-10B SCARA robot was utilized, equipped with a Zimmer electronic gripper to handle various test kit components.
- We designed the gripper to apply equal holding force on container caps, ensuring precise placement into kit foam.
Conveyor Systems:
- A kit entry conveyor was installed with timing belts and fixtures to hold kits during assembly.
- We added a solution conveyor with divider lanes for diluent containers and a kit exit conveyor to move completed kits to the operator table.
Vision Inspection System:
- Our team integrated a Teledyne vision system with three cameras for various inspections:
- 1. Final kit assembly verification to ensure all components were present and correctly placed.
- 2. Label character recognition to verify that the correct containers were used.
- We configured the vision system to display images and alerts on the operator interface if any errors were detected and pause the robot.
Operator Interface:
- We developed a touchscreen interface that allowed operators to select kit types, start/stop the robot, and view inspection results.
- Fault notifications were implemented with step-by-step instructions to guide operators in resolving issues.
Control and Communications:
- We reconfigured Rexroth IndraDrives to communicate via Ethernet/IP instead of legacy protocols.
- Profibus communications were replaced with Ethernet/IP for improved reliability and scalability.
Startup and Commissioning
- Our team provided on-site installation, startup, and commissioning support, including:
- Delivering and setting up the robot cell at Cygnus Technologies’ facility.
- Running IQ/OQ (Installation Qualification/Operational Qualification) tests to validate system performance.
- Providing 10 days of on-site training and support to ensure smooth adoption of the new system.
The Results
The robotic kit assembly and vision inspection system delivered significant benefits to our client, including:
- Improved Accuracy: The vision system verified each component’s label and placement, ensuring error-free kit assembly.
- Increased Efficiency: The automated system reduced manual labor and increased production speed, with an average cycle time of 17-20 seconds per container.
- Enhanced Operator Safety: The enclosed cell with safety switches ensured that operators could safely interact with the system without risk of injury.
- Reduced Downtime: The touchscreen interface simplified troubleshooting, allowing operators to quickly resolve issues and keep the line running.
- Scalable Solution: The dynamic design allowed our client to add new kit variations and integrate with their NetSuite ERP system in the future.
This project highlighted DSI Innovations’ ability to deliver advanced robotic automation solutions tailored to customer needs, improving accuracy, efficiency, and safety in manufacturing processes.
Technology Used
- Epson LS-10B SCARA Robot
- Zimmer Electronic Gripper
- Teledyne Multi-Camera Vision Inspection System
- Rexroth IndraDrive with Ethernet/IP Communication
- Custom Extruded Aluminum Cell Enclosure with Safety Interlocks
- Kit Entry, Solution, and Exit Conveyor Systems
- Touchscreen Operator Interface (HMI)
- Ethernet/IP Control Network (Upgraded from Profibus)
- NetSuite ERP Integration Ready
