Project Overview
Motionwell Automation delivered a fully integrated QA laboratory automation system for a leading medical device manufacturer in Singapore. The project (P23078) combined MiR AMR autonomous mobile robots with Universal Robots collaborative robots to create an end-to-end automated testing workflow for quality assurance operations.
The system automates the complete QA testing cycle: sample retrieval from storage, transport to testing stations, automated Instron tensile and puncture testing, result recording, and sample return. All operations are orchestrated by an Allen-Bradley PLC with a custom lightweight WMS (Warehouse Management System) built natively in PLC logic.
System Architecture
AMR + Cobot Compound Robot
The core of the system is a compound mobile robot that combines a MiR AMR base with a Universal Robots cobot arm mounted on top. This configuration enables:
- Autonomous navigation between storage racks and testing stations
- Precise sample pick-and-place at each station
- Flexible routing based on test schedules and station availability
PLC-Native Lightweight WMS
Rather than deploying an external MES or WMS system, Motionwell designed the warehouse management logic directly in the Allen-Bradley PLC. This approach provides:
- 70-position sample storage management across 7 racks
- Real-time inventory tracking with barcode verification
- Task scheduling based on test priorities and station availability
- Server-based work order management for test queue optimization
Instron Integration
The system communicates bidirectionally with multiple Instron universal testing machines:
- Automated zero-reset and speed parameter configuration
- Test start trigger and completion acknowledgment
- Real-time test data monitoring
- Automatic result file naming and network upload
Technical Specifications
| Component | Specification |
|---|---|
| Mobile Robot | MiR AMR with Universal Robots cobot |
| Controller | Allen-Bradley PLC |
| Storage | 70 positions across 7 racks |
| Testing | Multiple Instron stations (tensile/puncture) |
| Traceability | State machine with barcode verification |
| Communication | Ethernet/IP, bidirectional Instron protocol |
Key Engineering Decisions
PLC-native WMS vs. external MES: By building the WMS logic in the PLC, Motionwell eliminated a separate software layer, reducing integration complexity and single points of failure. The PLC handles scheduling, routing, and state management with deterministic timing.
Mixed human/robot operation: The system supports concurrent manual and automated operations. Station safeguarding ensures operator safety while allowing manual sample handling at non-automated stations.
Retry and recovery logic: Verified retry sequences maintain traceability even during error recovery. Operator prompts guide resolution of exceptions without breaking the audit trail.
Related
See how Motionwell serves the laboratory & QA industry and medical device industry.