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Optical Quality Control
Robotic Systems
Industrial software development
Introduction
ALS Czech Republic approached us with a request to automate the process of emptying sample tubes in their Prague laboratory, a task that had previously been carried out manually. This work was time-consuming and highly repetitive, while also posing health risks to employees due to the handling of hazardous substances.
The primary objective of the automation was to reduce manual labour and increase operational efficiency, ideally enabling unattended operation during night shifts.
Client Profile
ALS is one of the world’s largest and most diversified testing service providers. It operates more than 370 facilities in 65 countries across six continents and employs over 13,000 experts worldwide. This global network enables ALS to deliver accurate, fast and highly specialised analytical services across key sectors including life sciences, environmental testing, food and agriculture, energy, industrial services and materials analysis.
In Europe, ALS operates an extensive network of laboratories, including a modern accredited facility in Prague. The site is accredited by the Czech Accreditation Institute and specialises in chemical, microbiological, radiological and physical analyses. ALS places strong emphasis on workplace safety, data quality and operational efficiency. Each year, the company processes a vast number of samples, where precise tracking, safe handling and secure disposal are essential.
Project Requirements
The client required automation of the opening, emptying and disposal of samples stored in various types of test tubes. The key requirements included:
- Autonomous operation with the ability to run unattended for extended periods
- Flexibility to handle multiple types of test tubes, including different sizes, materials, and closing mechanisms
- Mobility of the workstation between laboratories
- Collaborative design allowing safe interaction with laboratory personnel
Proposed Solution
We delivered a mobile robotic workstation built on an EasyRobotics mobile base and equipped with an AUBO i5 collaborative robot. Three tables with six positions for test tube transport trays provide sufficient capacity for long operational cycles without operator intervention, including overnight operation.
The robot is equipped with a pneumatic gripper featuring universal metal fingers capable of handling a wide range of test tubes without tool changes. The AUBO cobot performs most handling tasks, including unscrewing and disposing of tube caps. A dedicated emptying mechanism with a separate gripper and tilting drive ensures reliable opening, controlled emptying, and safe disposal.
The workstation control is intuitive and user-friendly. Operators can choose between a push-button control panel and a teach pendant. System status is always clearly visible via a signal beacon, combining efficiency, safety, and ease of use.
Technical Specifications
| Robot | AUBO i5 collaborative robot |
|---|---|
| Gripper | Pneumatic gripper with universal metal fingers |
| Mobile base | EasyRobotics mobile base with three removable tables |
| Emptying mechanism | Pneumatic gripper with tilting drive and TPU anti-slip insert |
Project implementation
| 1. Design and prototyping | Design and prototyping of universal handling fingers |
| 2. Mechanism development | Development of a pouring mechanism with reliable tube gripping |
| 3. Testing | Testing of various materials and finger designs to achieve optimal performance |
| 4. Implementation | Implementation and commissioning of the workstation at KINALI premises |
| 5. Installation | Final installation and testing at the ALS customer site |
Results
The automated workstation operates unattended throughout the night, significantly reducing labour requirements while eliminating health risks associated with manual sample handling. The solution demonstrated a high level of flexibility, reliably processing different types of test tubes and adapting to laboratory needs.
Key insights
The biggest technical challenge was the reliable opening of tubes with snap-on caps. This was solved using specially designed metal fingers with higher friction, which ensured a secure grip. The project also showed that for more complex operations, the collaborative mode has certain limitations, which is why we plan to implement more robust verification of correct sample opening in the future.
Client reference
“We had a positive experience working with KINALI, and despite initial complications during deployment in live operation, they helped us resolve these issues to our satisfaction. I highly appreciate their willingness to provide CAD drawings for individual parts, enabling us to further optimize and improve the entire robotic workstation in the future, as well as their openness to continue participating in further development and enhancements.”
Conclusion
The robotic workstation made it possible to automate and increase the safety of the sample disposal and pouring process in the ALS laboratory. Thanks to its mobility and flexible design, it can be easily used across different laboratories and represents an inspiring example of how automation can transform routine and hazardous work into a smart and reliable process.
