Concepts
A typical QCX/RoboLab configuration consists of a standard industrial robot placed in the centre of a circular arrangement of sample preparation and analytical equipment. Samples normally arrive automatically from the connected automatic sample transport system, but may also be entered via operator sample conveyors or special input/output magazines.
QCX/RoboLab offers a very high flexibility in terms of the number and types of equipment handled by the robot. Supported, fully automated preparation & analysis disciplines relevant to the cement industry include powder or fused bead preparation for X-ray analysis, particle sizing by laser or by conventional sieving, colour analysis, Carbon/Sulphur/Moisture combustion analysis, physical testing and collection of shift/daily composites. For the typical cement lab project a throughput capacity of 10-20 samples will apply; but higher numbers in one robot cell are achievable.
QCX/RoboLab is one of two alternative laboratory automation concepts available from FLSmidth; the other is QCX/AutoPrep. These two automation solutions are exponents from each of the following two main categories of automation concepts for sample preparation and analysis :
- Automated equipment systems: Laboratories in which the sample preparation units and the analysis equipment are automated and then linked together by conventional transport belts or the alike. The automation is provided by dedicated highly specialised equipment units.
- Robotics systems: Laboratories in which automation is achieved by robotics. The equipment units serviced by the robot(s) may be fully automated, semi-automatic or manual.
In the dedicated robot automation concept the robot is a specialised automation component and integrated in the detailed handling of the other equipment components to a degree that makes it very difficult to re-program the robot for modified procedures.
In flexible robot automation (as QCX/RoboLab) the operator is automated rather than the equipment. The main automation element provided by the robot is the transport of samples between the different stations in the robot cell. The concept implies that the robot can easily be re-programmed or set up to service new equipment units.
The choice of automation concept depends on the complexity of a particular analysis method, the volume of the sample throughput and the overall automation concept desired. Typical key decision criteria to consider are :
- Capacity and complexity of methods
- Sample types and material properties
- Analytical requirements
- Equipment location, building lay-out
- Current and future labour costs
- Daily operation and maintenance implications
- Data processing requirements
- Flexibility towards future needs
In general the dedicated automated equipment solution (as QCX/AutoPrep) is - as graphically outlined in the diagram above - favorable with high sample throughput and/or low preparation complexity. For a ‘powder preparation only’ configuration, which is regarded as a low complexity operation, this means in most cases that a linear type arrangement is the most cost effective of the two alternatives.
Robotics solutions - flexible (as QCX/RoboLab) or dedicated - become preferable with increased number of preparation units serviced and with increased complexity of the procedures. This is because the robotics approach requires less adaptation of the equipment serviced and ‘simpler’ less expensive automation of a wider range of standard laboratory components. Other factors in favour of the flexible robotics concept are, as the name implies, it’s high flexibility towards future modifications and the ‘built-in’ manual back-up capability, since all equipment units serviced can also be serviced by a human operator. Complex sample preparations - for example fused bead preparation for XRF and sample dosing & weighing for Carbon/Sulphur/Moisture combustion analysis - are good examples of procedures for which a robotics based solution is the natural more flexible and less expensive solution
