— Project 06 of 07 · Process

Multi-level sample transport, Brisbane pathology lab.

Automation programming for a 5-level tote bin conveyor system handling 18,000 pathology samples per day — Omron NX PLC over EtherCAT, two servo-driven lifts with RFID container addressing, 13 ZEN-controlled transfer units, and per-level safety zones in a new facility at Bowen Hills, Brisbane.

01 / overview

5 levels, 18,000 samples a day.

Automation programming for a 5-level tote bin conveyor system handling 18,000 pathology samples per day. Omron NX PLC over EtherCAT, two servo-driven lifts with RFID container addressing, 13 ZEN-controlled transfer units, and per-level safety zones across a new facility in Bowen Hills, Brisbane.

Industry
Healthcare — Pathology
Service
Programming
Location
Bowen Hills, QLD
Year
2016
Control
Omron NX PLC · EtherCAT
Identification
RFID container addressing
[TODO] Customer narrative Set the scene: new build in Bowen Hills, the broader laboratory automation, how Pac was engaged (direct / via the conveyor OEM), what was already specified vs. what Pac defined.
02 / challenge

The challenge.

[TODO] Brief & constraints Why a 5-level system in the first place — building footprint? lab adjacency? cold-chain or biohazard handling? The accuracy and chain-of-custody expectations on pathology samples specifically.
03 / approach

Our approach.

[TODO] Engagement narrative How the Omron NX / EtherCAT topology was structured, why RFID at the tote level, how the two servo-driven lifts coordinate, what the per-level safety zoning protects, FAT and SAT cadence.
PLC
Omron NX
Backbone
EtherCAT
Lifts
Two servo-driven
Transfer units
13 ZEN-controlled
Identification
RFID at tote level
Safety
Per-level zones
04 / outcomes

Outcomes.

[TODO] Results Daily throughput, chain-of-custody / addressing accuracy, anything the lab team has fed back since handover, how the system has held up over the years it's been in production.