The company was looking for a system for its branch in San Diego that closes DNA sample vials as efficiently, quickly and automatically as possible. Illumina opted for a seven-axis gantry system, which largely consists of Afag modules.

"A system that can cover a large work area and run as fast as possible" - that was the specification Illumina gave its system integrator Korvis when they were looking for a solution to seal DNA sample containers efficiently and quickly at its headquarters in San Diego. Previously, this was done manually at Illumina. "We were looking for a system that worked without human intervention," explains Christopher Chu, Automation Design Staff Engineer at Illumina. "We wanted to optimize our uptime, eliminate human error and ensure that the closures fit on the vials according to standards." Illumina had already had good experiences with handling components from Afag on other projects in Singapore. "I have known the products for several years now. We first worked with the Riverhill team, Afag's distribution partner in Singapore, in 2015. The quality of the products and the knowledge and commitment of the Singapore team completely won me over," says Chu. Illumina therefore decided to equip the station with the Afag handling system. And so system integrator Korvis turned to Riverhill in Singapore with this project. The add-on solution goes by the illustrious name of "Mixmaster".

Customized solution: seven-axis gantry system
The Mixmaster is one of many stations in the Illumina production line and houses, among other things, a full-range seven-axis gantry system. It consists of two Afag PEL30-430-D20 gantry axes (X-axis), one PDL30-530 gantry axis (Y-axis), two ES20-200 electric slides (Z-axis) and two SE20 rotary axes (C-axis). Each of the linear axes used is driven by a linear motor, which enables high cycle times with simultaneous precision. Due to the unusually large number of axes, Afag has given the handling system the designation EPS midi gantry XXYZZCC. The usable working area is approximately 600 by 500 millimeters. The Mixmaster has several chucks that can hold up to 16 different lids. Currently, only seven different types of DNA sample containers are capped. A tool change is carried out fully automatically in 90 seconds.

In the first processing step, workpiece carriers of an Afag linear transfer system transport two containers under the handling system. The workpiece carriers stop here and the containers are fixed in place with grippers. The two ES20-200 electric slides mounted on the PDL30-530 gantry axis position the SE20 rotary axes above the containers. The two rotary axes then screw the plastic closures onto the containers simultaneously and with a predetermined torque in order to comply with ISO 13485. The gantry axes then move back so that two new caps can be picked up for the next two containers. Such a cycle takes just three seconds, which means that a total of 40 containers per minute can be closed in this way and fed to the next work step.

System meets all requirements
"We received the order shortly before Christmas and delivered the seven-axis gantry system at the end of January via our dealer Riverhill Holdings," recalls Michael Zhu, Sales Manager Greater China & South East Asia at Afag. "The special parts supplied by Korvis were also installed in the system at the customer's request before delivery." Afag took care of the cabling and tubing, while the installation and cabling of the sensors for additional add-on parts was carried out by the customer.

Illumina praises the cooperation with Afag and is satisfied with the Mixmaster, as the system fulfills all the requirements placed on it.

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