Production line for innovative digital COVID-19 rapid test goes into operation

The precise positioning of the workpiece carriers ensures fully automatic assembly of the rapid tests.

Modular workpiece carrier conveyor system Versamove with antistatic timing belts and slide rails.

Fully automatic parts supply at the assembly line via driverless transport system (FTS).

Fully automatic loading of workpiece carriers using pick-and-place robots.

Assembly line with a final inspection station for contacting, powering, and uploading data to the PCB (Printed Circuit Board).

In Jena, a fully automated production facility for innovative rapid COVID-19 tests has been put into operation. The system produces one million digital rapid tests per month. The special feature of this system – it is the result of close collaboration between companies from different disciplines. The system was developed, constructed, and launched in the shortest possible time. From now on, the innovative rapid tests can be produced industrially, making a significant contribution to the fight against COVID-19.

The Rapid Tests

Unlike the tests previously available on the market, the new Senova GreenLight functions like a digital mini-laboratory. After the sample is applied to the test, the test analyzes it independently and processes the data in a central cloud. This allows many test results to be recorded, analyzed, processed, and stored simultaneously. Handling large volumes of tests becomes less error-prone and easier to implement and evaluate.

The System

On a workpiece carrier conveyor system, the tests are fully automatically assembled by robots. On another conveyor, the finished products are semi-automatically processed further and later manually packed. The entire system had to be designed with a continuous ESD protection concept because sensitive electronic components are installed in the tests. The ESD protection plan aims to prevent potential differences. Production takes place in a dry room with a maximum humidity of 10% to avoid damaging the sensitive tests during manufacturing.

The Cooperation Partners

Only through close and constructive collaboration among the various stakeholders could the necessary production capacities for the innovative rapid tests be realized so quickly. The digital technology and processing of the tests were developed by ams, one of the leading sensor manufacturers. In contrast, Senova produces medical rapid tests, such as the well-known pregnancy tests. They provided the know-how to implement and industrially produce ams's digital concept. The system builder was mkf GmbH, a subsidiary of the mk Technology Group, which specializes in factory automation in the conveyor technology sector. For robotics and mobile transfer systems, Omron, one of the leading factory automation companies, was involved. All participants contributed their expertise hand in hand to realize the industrial production of the new rapid tests as quickly as possible. And now, the time has come: the system is running, all test scenarios have been successfully completed, and it can produce at full capacity.

The Conveyor Technology

mkf and Omron implemented the entire system, including gates for the dry room, interfaces, control, and commissioning on-site. The corresponding conveyor technology was supplied by Maschinenbau Kitz, the parent company of mk Technology Group.

For this task, the Versamove plus workpiece carrier conveyor system was the right solution. The conveyor was realized with toothed belt conveyors equipped with antistatic slide strips and antistatic toothed belts. The choice of materials and designs, combined with grounding connections, ensures that no potential differences can build up, thus fulfilling the required ESD protection. The slide strips and belts are also wear-resistant and emit few particles. The conveyor system can stop, buffer, position, and separate. With positioning units, workpiece carriers can be precisely positioned at the robot processing stations in X, Y, and Z directions to within 0.1 mm. A particular challenge was the spatial constraints: all positions had to be arranged within a very small hall measuring 10 m x 15.5 m. The mk engineers solved this by consolidating two originally planned conveyors into one. With lifts, the workpiece carriers are transported to another level below the first transport line. Access to the interior of the conveyor is provided via fold-out maintenance doors. Additionally, the required delivery time, including design, manufacturing, and assembly, was very short. In this special situation, mk managed to deliver the entire conveyor technology within a few weeks after the request.