Operational Validation of an Integrated PLC-Vision System for Pre-Analytical Tube-Box Classification Using Simulation

Alberto Montoya Grillo C.; Mendoza Acosta A. · Proceedings of the LACCEI international Multi-conference for Engineering, Education and Technology (2026) · DOI: 10.18687/laccei2026.1.1.1591

Resumen

Pre-analytical laboratory workflows are prone to operational errors due to manual handling and visual identification of blood collection tube boxes, negatively affecting efficiency, reliability, and workflow continuity. Although commercial automation solutions exist, their acquisition and integration costs often hinder adoption in small and medium-sized clinical laboratories, especially in resource-constrained environments. This paper presents a simulation-based, pre-deployment operational validation of an integrated machine-vision and programmable logic controller (PLC) system for automated pre-analytical tube-box classification. The proposed solution follows the VDI 2206 framework and implements a three-level architecture aligned with IEC 62264: (i) a field level with virtual sensors and actuators, (ii) a control level based on a Siemens SIMATIC S7-1200 PLC programmed in Ladder logic, and (iii) a supervision level using a human-machine interface (HMI). A vision module based on HSV color-space processing classifies tube boxes according to color-coded visual attributes. High-fidelity industrial simulation is used as the primary validation environment to enable controlled experimentation prior to physical deployment. Operational validation includes performance evaluation, robustness analysis, and extreme-condition testing. The system achieves 97.3% classification accuracy, 219.5 boxes/h sustained throughput, a 1.375 s average cycle time, and 99.3% Vision-PLC latency compliance (≤200 ms). Monte Carlo-based reliability analysis estimates a projected MTBF of 2,347 h under nominal simulated conditions, and stress tests confirm stable behavior under adverse scenarios. These results support simulation-based operational validation as an effective pre-implementation stage to quantify feasibility and reduce technical risk before implementing a physical prototype.

Instituciones: Universidad Tecnológica del Perú