Challenge:

A leading laboratory sought to modernize and automate their tip refilling process to improve efficiency, reduce manual labor, and enable longer, uninterrupted assay runs. Traditional methods required significant operator intervention and careful tip placement, leading to inefficiencies, increased labor hours, and potential errors. Additionally, the system needed to support any tip type dynamically, handle random loading without user instruction, and be universally compatible across Hamilton liquid handling platforms. Seamless integration with existing systems for error tracking and recovery was critical to maintain high uptime and data integrity.

Solution:

To meet these requirements, we engineered a robotic work-cell designed with flexibility and operational independence at its core. The system allows users to place any tip type at any entry point without instruction and supports mid-run refills without interrupting workflows. It operates as a standalone unit featuring a custom-developed intuitive user interface to track tip locations and movement. We wrote a custom Hamilton Scripting Language (HSL) library to drive the tip filling mechanism, ensuring precise and adaptable control. Barcode scanning was integrated to verify tip identity, guaranteeing accuracy. Custom movement paths were designed to efficiently clear used tip waste, optimizing space for new tips. The system also generates detailed output files for traceability, prompts for refills, and manages error recovery by communicating seamlessly with the integrated host system. Importantly, the solution was built without reliance on Venus Method Syntax, enhancing adaptability across different environments.

Results:

The robotic work-cell now operates exactly as intended, dramatically reducing the need for operator overtime to manage tip refills. The flexible and integrated solution expands tip capacity on demand for any Hamilton system, cutting down operator touchpoints and labor hours while increasing overall throughput. By automating these processes, labs can run longer, more complex assays without user intervention or workflow delays, enabling a seamless and efficient process flow. Additionally, the system ensures data security and tamper-proof record keeping, further supporting regulatory compliance and operational reliability.

See how our team can assist?