Robot for the NEWICON pharmacy

Posted by Klain on
Company: NewIcon
Industry: Medica/Farmaceutica
Denso Robots used: VS-068A2 e VP-6242G
Company Location: Finlandia
Web site: www.NewIcon.fi
CHALLENGES

The manual retrieval of medications is a time-consuming task, requiring millions of man hours in hospitals and pharmacies each year. In Germany alone, pharmacies sell some 1.3 billion medication packages annually, or roughly 68.000 packages per pharmacy. Yet medication retrieval is also an error-prone process, for error rates as high as 15% have been reported by some studies. This is a pressing problem, because errors in filling prescriptions can endanger patient health.

To address these issues, the Finnish company NewIcon has developed automated, robot-assisted systems that make medication storage and retrieval safer, faster, and more efficient. DENSO robots lie at the heart of the solution.

THE SOLUTION 

Robot per lo stoccaggio e recupero di farmaci

Robot per lo stoccaggio e recupero di farmaci

 

 

 

 

 

 

Previously, NewIcon employed linear robots in its medication retrieval systems. Since 2010, however, the company has been using DENSO robots, which offer more axes for faster storage and retrieval as well as light-weight components in a compact housing. NewIcon also opted for DENSO because DENSO´s open architecture could be flexibly integrated with its existing software and machine vision system.

NewIcon offers two interlocking systems: a storage system for sorting and registering medications, and an input system for retrieving and delivering medications that have been stored. The DENSO VP-6242G is used in most applications, although the VS-068A2 is also employed when there is a need for faster speed and longer reach. The robots are controlled through an Ethercat bus connection. Robot programming is carried out in Visual Basic and C# using WINCAPS, DENSO´s offline programming, monitoring, and simulation software.

The information for picking and delivering a package can be manually entered by staff on a PC or communicated by scanning a barcode. In both cases, the control system directs the robot to grab the appropriate package and drop it into a container, which is then forwarded to a collection tray. When sorting packages, the robot performs scanning autonomously, without human interaction.

The robot arm is equipped with vacuum pumps and special suction cups to ensure reliable grip. The PC software knows the dimensions of all packages, enabling it to specify exact coordinates for robot pick-up.

BENEFITS

Robot per lo stoccaggio e recupero di farmaci

Robot per lo stoccaggio e recupero di farmaci

 

Thanks to the speed and precision of the robots, both systems boast extremely high reliability and efficiency levels. Generally, a robot can identify and retrieve 240 incoming packages per hour in pharmacies and up to 450 packages per hour in hospitals (60% faster than a human). These numbers can be increased by using multiple systems simultaneously. The times for retrieval depend in part on the solution chosen by the customer; typically, a robot needs 6–8 seconds to deliver an individual package, but with the option of multi-picking, this can be reduced to 3–4 seconds per package. Using multiple systems, efficiency can be further optimized, last but not least, DENSO robots guarantee a practically zero error rate (99.9%). This is extremely important in health care, as misfilled prescriptions can endanger patient health.

The feedback from staff working with the robots has been very positive. Staff members particularly value the reliability of the system. The aesthetic appeal of the white robot components is also regularly praised.

Currently, more than 70 systems, employing more than 100 DENSO robots, are being used in hospitals and pharmacies around the world. NewIcon has been extremely satisfied with the robots as well as DENSO´s close customer support.

NewIcon is already using DENSO robots in other areas; a DENSO VS-050A3 is currently being employed as an IV ICON antibiotic compounding robot – and the company promises “there is more to come.”

 

Stem cell production

Posted by Klain on

Company: Fraunhofer Institute for Production Technology IPT
Industry: Medical research / Industry 4.0 application
DENSO Products Used: VS-087
Company Location: Germany
Website: http://www.ipt.fraunhofer.de

THE PROBLEM

Stem cell research is one of the most innovative areas in current medical research and plays a decisive part in developing new agents and drugs. Research is thereby based on cultivated stem cells, in particular mesenchymal stem cells, or MSCs. These are mature stem cells extracted from adult human tissue, which means that isolation (unlike embryonic stem cells) can be done in an ethically acceptable way. Due to their capability to differentiate into new cell types, stimulate cell growth and influence the human immune system, they hold much promise for regenerative cell therapy.

The expansion of these cells, however, is a long and labor-intensive process. What is more, researchers have to deal with variations in the biological material that originates from many different donors. This variability is further increased by deviations in the cell treatment in manually produced cultures. At the same time, human interaction raises the risk of error and limits reproducibility. Additionally, as cell cultures are living organisms, a cleanroom environment is essential, which requires special standards for instruments and devices.

THE SOLUTION

The solution is the development of a fully automated, self-contained yet flexible system for cultivating stem cells. StemCellDiscovery is a globally leading pilot project launched by the Fraunhofer Institute for Production Technology (IPT) in Aachen, Germany. The Aachen facility aims at growing and researching MSCs, and implementing various lab processes – from cultivating cells to generating experimental data. The facility features the easy integration of devices; consistent and accurate reproducibility; an individual, modular-based control of processes; high-quality cell products; and the use of advanced measuring technology for quality assurance and analysis.

A DENSO robot plays a central role in the facility. The robot, a VS-087 model, serves as a flexible handling unit for all transportation steps in the platform: transporting cell cultures in multititer plates, moving falcon tubes between different processing and measuring devices, and ensuring highly accurate positioning. Precision is particularly important at the microscope, where the robot first grips the cell culture container and then positions it in the designated holder. The robot’s flexibility also is useful for pre-positioning resources, such as transporting pipette tips from the storage to the liquid handling unit.

In addition, the robot provides the service for shaking the cell cultures with the same speed and movement in order to distribute the cells equally. This is key, as an inconsistent movement could result in cells accumulating at the edge of the container, leading to suboptimal conditions for cell growth. To achieve a consistent distribution of cells in the container, it is important that the robot applies constant acceleration to the cultures.

As the facility relies on the interaction of the devices, their integration plays an important role. In order to maintain a high level of flexibility in the overall system, a service-based software architecture was implemented. An adaptive, specially designed software system controls all processes. It can respond flexibly to indicators for cell culture such as cell growth and, if necessary, execute individual services following a modular approach. These services are provided by all devices via an Integration Framework, which allows the user to create any combination of services at the control level. Each device offers services with defined parameters that can be controlled manually via the intuitive user desktop or assembled into complex combinations. In- and outgoing data collected from the devices are provided in a universal format so users can control all devices from a single desktop – whether it is the microscope or the DENSO robot, the liquid handling unit or the incubator and repositories. The software has been programmed in C#, which makes it possible to abstract complex logical relationships and implement object-oriented programming.

The Integration Framework also includes the VS-087. Due to its intuitive interface, it can replicate the robot’s real-world services in the facility. The robot is controlled by the built-in RC8 controller. The interface communication is based on ORiN2 and the option of implementing control via C# (easily embedded into the software architecture). The software also assumes the full control of the robot: Any variation in the processes can be detected and resolved immediately. The Integration Framework sends activity protocols to the control software that provides users with status information, among other data.

The VS-087 was selected primarily because of its programmability and easy integration capabilities. To automate the manual processes in the facility, various devices had to be included. As is typical for innovative research, the selection of these devices was made long before the actual software development was launched. Hence, it was important that a robot was implemented that can be programmed flexibly as requirements change. Cleanroom compatibility was also crucial. Last but not least, the VS-087 allowed for the design of a compact facility. The multi-functional gripper designed for this purpose can, thanks to robotic kinematics, be moved to any spot within the facility, ensuring the highest levels of precision.

The programming of the DENSO robot also permits a high level of sensor integration and, thus, opens up new opportunities for self-optimization. In all likelihood, this will significantly optimize process stability. Due to the direct connection between sensor and robot, both gripper operations and path planning during movement can be controlled. This will support process stability considerably in self-contained, sterile facilities such as this one.

THE RESULT

During the implementation of the StemCellDiscovery project valuable experience could be gained in the context of innovative control technologies for automated laboratories. The industrial robot is technically reliable and provides the flexibility required for handling all types of materials and products. This experience will not only advance research; it will also help the medical and pharmaceutical industries to develop new products.

Finally, the VS-087’s service-oriented architecture and flexible handling support enable the realization of a variety of processes. In the future, the cultivation of other cell types can be implemented and external users will be able to work at the facility with short lead times. Furthermore, standardized and validated function modules will be available, providing standardized protocols for the generation of cell products that meet industrial standards.

A special emphasis has been placed on communication between different components in the facility. This is essential for an efficient modular approach and additionally promotes adaptability. In the world of Industrie 4.0, interconnecting devices and machines is a requirement for innovative research.

In the future, the facility will potentially deliver new insights using statistical methods (BigData and Analytics), which promise to advance and quicken the search for innovative therapies.

Robot for Medical Industry – HEALTH ROBOTICS

Posted by Klain on

Company: HEALTH ROBOTICS
Industry: Medical
DENSO Products Used: VP-G2-S1 (H2O2-resistant)
Company Location: Italy
Website: http://www.health-robotics.com/en/

THE PROBLEM

To develop a very compact and flexible system able to manipulate a large variety of objects (i.e.: drug vials, syringes, and IV bags of different shapes and dimensions) that are normally used in the manual process of drugs compounding.

THE SOLUTION

Against this background the i.v. Station emerged, based on a DENSO robot – that could be described as a type of automated medicine distribution system, which is connected to the hospital prescription system. The appliance receives its order data from the prescriptions for the treatment specific to the patient. This information includes the medicine preparations that have to be made available in a selected time period and in a special form. At the point in time that a new bottle, a new syringe or a new bag is introduced almost nothing on the machine’s hardware has to be changed. It is enough to readjust the software or the modalities to handle and administer the object. Among others the i.v. Station allows the preparation of medicines such as antibiotics, painkillers and anti-inflammatories for inpatient treatments.

  • A DENSO 6-axis robot of the VP-G2 series takes the syringe and positions it on a mechanical dosing feeder.
  • Then it takes the top off the syringe and takes the bottle that has to be filled with the medicine out of the repository, which had previously checked by an image processing system.
  • After the needle has drawn off the desired quantity the robot lifts the syringe into the weighing system.
  • A gravimetric check is carried out there that makes it possible to make an independent check of the dosage. During these procedures the machine is continually provided with a constant air flow that guarantees sterility in the interior. This system guarantees that the air is completely exchanged practically every two seconds.
  • Before discharging, the syringe is provided with a protective cap so that the contents do not come into contact with the outside air. Then it is labelled by the labelling machine, which provides information about the medicine preparation and a barcode for identification purposes.

To avoid errors when filling materials the i.v. Station has two image processing systems with medium resolution cameras (three megapixels). These check if the bags and syringes have been correctly positioned and they also scan the bottle labels that appear to prevent the operator from accidentally confusing the medicines during the filling phase. This is supplemented by a control phase – which takes place during filling – that is done by a barcode reader placed on the front panel of the machine. The final check is done by the computer monitoring system, but through the barcode reader the machine already knows what to expect.

Great attention has been paid to the dimensions of the equipment, because there is normally little space in hospitals.  “Large equipment,” emphasises Giribona, “means nothing less than sacrificing part of the market, because many hospital do not have enough space to install it. It is for precisely this reason that we drafted the i.v. Station to be the size of a large fridge, a cuboid one metre by two metres high that can be easily set up.” The compact design of the DENSO robot met this aim.

Safety has top priority

To be able to guarantee an appropriate safety level in terms of functionality and operator access the i.v. Station is equipped with certain capabilities. For example, it guarantees that access by unauthorised people is prevented during working procedures. These measures extend from profiling the user using user names and passwords, reader modules to identify RFID badges, up to biometric recognition.