Team Siemens. Microplate Loading System. Left to Right: Paul Masullo, Maxime Dempah, Leah Putman, Daniel Russakow, Daniel McCarthy

Transcription

1 Team Siemens Microplate Loading System Left to Right: Paul Masullo, Maxime Dempah, Leah Putman, Daniel Russakow, Daniel McCarthy Department of Mechanical Engineering

2 Outline Introduction 1. About the Project 2. System Overview 3. Microplate Loading Process Cycle Design 1. Overall Prototyped System 2. Transportation System (Conceptual) 3. MicroScan Loading Arm Mechanism 4. MicroScan Access Door Prototype Project Management 1. Prototype System Cost 2. Initial Performance Validation 3. A Path Forward Department of Mechanical Engineering 1

3 About the Project Background: Siemens Healthcare is a worldwide supplier to the healthcare industry providing laboratory and medical testing equipment. Project goal: Siemens is developing an automated filling station for microplates to accompany their testing station, called the MicroScan. The design team was asked to design a transport system to connect the two stations. Project Framework: Automated microplate loading by developing a transportation system, an access door, and loading mechanism Benefit to Siemens: Time efficiency, elimination of human error and contamination by manual loading Future plan: Further development and integration of the prototype for eventual market implementation Department of Mechanical Engineering

4 System Overview Microplates Filling Station MicroScan Testing Station Copyright 2010 Siemens Healthcare Diagnostics. All rights reserved. Transport System Department of Mechanical Engineering 3

5 Microplate Loading Process Cycle START Receive two microplates on cart from Filler Machine Close MicroScan access door Go to ready position for new microplates Constraints Maintain MicroScan testing environment during operation No sample crosscontamination Maintain cover on microplate Open MicroScan access door Cart transported to MicroScan via transportation system Load the microplates into the MicroScan via loading arm Department of Mechanical Engineering

6 Overall Prototyped System Door system Microplate Loading arm MicroScan internal carousel Adjustable frame Microplate transport cart Department of Mechanical Engineering 5

7 Prototyped System Loading arm Microplate transport cart Adjustable frame Department of Mechanical Engineering 6

8 Transportation System (Conceptual) Weighted Metrics Minimum cost (<$3500) Cycle time (<60 sec round trip) Weight (< 40 lbs) Minimum velocity (2 in/s) Maintenance price (10% cost) THK Linear Actuator : Timing belt system Belt below cover for added protection, increasing service life Plug-and-Play system Data acquisition ready High accuracy displacement ±0.08 mm (± ) THK LM Actuator Model GL15N Department of Mechanical Engineering 7

9 MicroScan Loading Arm Prototype Weighted Metrics Plate displacement accuracy (<0.3 ) Small gripper/pusher size (<4 x 7 ) Stroke length (9 to 21 ) Total pusher system size (< 24 ) Low cost ( < $1200) Active-Style Gripper: Miniature linear actuator for microplate gripping Geared stepper motor for quick and accurate placement of microplate within the MicroScan, easy programming Rack & pinion system Grip maintains microplate stability throughout loading Department of Mechanical Engineering 8

10 Assembly Details Department of Mechanical Engineering 9

11 MicroScan Access Door Prototype Weighted Metrics Thermally insulated Approximate door system weight (< 10 lbs) Door open < 12 sec Door open/closing time (< 2 sec) Door opening area (< 4.5 x7.5 ) Low cost (< $800) Direct-Drive Door Stepper motor control Directly geared to door for immediate door response Light weight All parts built on one mounting bracket for simple installation Department of Mechanical Engineering 10

12 Door Opening Department of Mechanical Engineering 11

13 Assembly Details Department of Mechanical Engineering 12

14 Microplate Loading Department of Mechanical Engineering 13

15 Prototype System Cost Manufacturing Cost, $1, Pusher Mechanism, $ Frame, $80.00 Transportation System, $2, Door System, $ Cost estimates include approximate cost for in-house parts Estimated 300 man-hours of labor Department of Mechanical Engineering 14

16 Initial Performance Validation Accuracy Time of Operation Microplate loading into the MicroScan requires precise alignment of the system Test Procedure The system will run numerous times to ensure the plates are properly loaded into the MicroScan each time. Judged on success/fail criterion. The system must be able to deliver and load two microplates in 60 seconds Test Procedure Timing of individual moving parts will be recorded, as well as total system operation time for loading one plate and multiplied by two. Department of Mechanical Engineering 15

17 Initial Performance Validation (cont d) Maintenance of MicroScan Environment The samples must remain in a humid and dark environment, heated above room temperature for incubation. Test Procedure In dark room, place light directly against seal and check for leakage on other side. For a more sensitive test, use a light diode. Sample Cross- Contamination It is critical to avoid crosscontamination between the wells of the microplate. Otherwise, the MicroScan test integrity is lost. Test procedure Place ink in alternating wells of plate. Run the full system cycle, checking for splash and crossover after each step. Department of Mechanical Engineering 16

18 Current Standing All components are fabricated and assembled The subsystems still need to be linked electrically Delay is due to a faulty control board Issues with system Brown Out Electrical problems will be sorted out this week Prototype will still be delivered on time Department of Mechanical Engineering 17

19 A Path Forward Reliability Testing Transportation System Integration Siemens Development Reliability Testing: Target lifetime of 7 years continuous use before need of servicing Failure modes and effects analysis (FMEA) Reliability Growth Testing Data for statistically modeling Transportation Integration: Interface the loading system with the microplate filling station The design team suggests transportation system presented Siemens Development Implement the total system (filling station, transport/loading system, MicroScan) for sale in the medical market Department of Mechanical Engineering 18

20 Special Thanks To: Peter J. Truitt, BME 01 Daniel J. McDermott, BME 01 Peter L. Gebrian James Glancey Department of Mechanical Engineering 19