Robotics and Automation Lab Projects
This page showcases my contributions to the Robotics and Automation team as part of the Systems Engineering department at Bayer. My role involves testing the various injection systems and software that Bayer creates. Specifically, I help create mechanical fixturing and program automation to perform robotic risk reliability testing and verification and validation testing. Below I will detail a new system I helped integrate, and showcase some of my programming and mechanical skills.
Robot System Overview
Our site uses ABB IRB 1200 robots to perform the automated testing. When I joined the lab, we had two existing robot cells. Since joining, I have assisted in the integration of a third IRB 1200 robot. I will detail this robot below and the main components used for testing.
ABB IRB 1200 Robot
This is a 6 axis robot produced by ABB. We use this robot to manipulate the injector heads and displays to press buttons and remove sterile disposables. We use the compact controller variety, which allows us to use socket, serial, and digital I/O to communicate with the end of arm tooling and external axes.
Robotiq Gripper
This is the gripper we use for the end effector on the robot arm. The pads at the end are replaced with custom machined jaws, which are unique for each test. To communicate with the robot it uses an ethernet socket connection and different I/O status bits.
COGNEX Camera
Each robot has it's own COGNEX camera that is used to read the screens of the injector. We primarily use Optical Character Recognition (OCR) to read the text strings on the injector systems, but also rely on other vision tools such as Color or Light measurements. This communicates to the controller via ethernet socket connection.
Moog SmartMotor
The SmartMotor is used to drive different rotating or linear parts in the tests. Each test application is specific and requires appropriate gearing considerations. This houses its own script and is triggered to go to specific positions using the I/O on the robot controller.
Integration
As stated previously, the components above were acquired for a new robot system. By starting with new components, I learned to integrate each using I/O and socket communication. I strengthened my networking skills by setting up these devices in a local network with the robot, and also honed my programing skills by getting to create programs for the new robot from scratch.
Programming
One main area I contribute in on the Robotics and Automation team is creation of the robotic test scripts. The robot is programmed with it's own C-based language, ABB RAPID. When I started, I had to work with scripts left behind by a former employee. Having minimal software experience and no formal training, I was able to navigate the old scripts and teach myself how to program the robots. I transformed these programs into something usable and eventually created my own programs from scratch. My goal was to create scripts that allow others to easily learn and use, without having to spend months diving into confusing programs as I did when I began.
In a production setting, robots are typically used to complete single, repetitive tasks. For the type of testing we perform, however, lots of intricate movement and logic is used to test each feature of the injector system. One such task is syringe removal, which requires precise programming and end-of-arm tooling. I was able to implement syringe removal routines on various tests, as well as design unique tooling for each type of syringe. A syringe removal routine on a test fixture is showcased in the video below:
Mechanical Fixturing
Mechanical fixturing is essential to repeated, automated testing. If the workpieces are not rigidly fixtured, they can drift over time and cause position errors. For testing injection systems this is especially important, as both the injector and the display unit have repeated button presses that need tested. Additionally, the injector typically has syringes or sterile disposables that need to be removed and re-inserted after each cycle. If the system creeps during these removals, it would be impossible to maintain continuous testing.
I have created or assisted in the creation of mechanical fixtures for the Arterion CV injection system, Stellant FLEX CT injection system, MRXperion MRI injection system, and Intego PET infusion system.
I am choosing to highlight the Arterion fixturing and program as it incorporates all the aspects of the automation system.
CAD Design Work
My CAD work was not contained purely to injector fixture design. The following section details some of my other CAD work done as part of the Robotics and Automation lab.
Robotics Area
The Robotics and Automation lab is constantly changing as we increase our capability to handle new medical devices. I took the existing robot cell and created the above CAD model from scratch to help us layout the room. Doing so in a 3D format rather than creating a 2D floor plan allowed us to ensure the new robots and fixturing do not conflict with smaller details on the wall, such as outlets.
SOLIDOWORKS Simulation
Along with creating detailed CAD files, I also created some animations, both to provide a visual for departmental meetings, but also as a way to check for collisions. The above video showcases a SmartMotor driving the rotation of a gear attached to the back of an MRI injector head.