Automatic loading system for sterilizer

Abstract

This invention provides an automatic feeding and loading system for a sterilizer, including a sterilization trolley, a sterilization cabinet, a transfer mechanism, a sterilization buffer station, and a transport mechanism. It may also include a communication module and a control cabinet. The sterilization trolley is used for loading and transporting materials. The sterilization cabinet receives materials and performs sterilization. The transfer mechanism is responsible for removing the sterilized materials from the sterilization cabinet and placing them in the sterilization buffer station. The transport mechanism delivers the materials from the sterilization buffer station to subsequent processes. The communication module and control cabinet enable communication and control between the various components. This system solves the problems of low efficiency and poor safety in traditional manual feeding, achieving automated and precise feeding, improving operational efficiency and safety, and supporting multi-line collaboration and data traceability.

Description

Technical Field

[0001] This utility model relates to the field of automated production equipment technology, specifically to an automatic feeding and loading system for a sterilizer. Background Technology

[0002] In production operations requiring sterilization, the material loading process has long relied on manual assistance. Traditionally, stainless steel trolleys with simple connecting mechanisms are used to handle the loading, unloading, and transport of items to be sterilized. This operational model has several significant drawbacks: First, precise positioning during the connection between the trolley and the sterilization cabinet is difficult, often requiring operators to repeatedly adjust the position, consuming considerable time and severely impacting the overall work rhythm. Simultaneously, pushing materials from the trolley into the sterilization cabinet is also cumbersome, further increasing loading time costs, resulting in low production efficiency and making it difficult to meet the demands of continuous, batch production.

[0003] Secondly, when the sterilization cabinet door is opened after the sterilization process is complete, a large amount of warm steam escapes. This steam is not only very hot but may also contain moisture generated during the sterilization process. Operators who come into close contact with this steam are highly susceptible to burns, posing a serious safety hazard. To avoid this injury, operators must wear heavy protective gear. This not only increases the physical burden on operators, making them more prone to fatigue, but also reduces operational flexibility due to the restrictive nature of the protective gear, further impacting work efficiency.

[0004] Furthermore, in multi-line production scenarios, traditional manual material feeding methods struggle to achieve efficient coordination between different production lines and sterilization equipment. Due to the lack of a unified scheduling and automated connection mechanism, material feeding on each production line often operates independently, easily leading to equipment idleness or material backlog, resulting in low resource utilization. Simultaneously, during manual operation, key data such as material flow information and sterilization parameters rely heavily on manual recording, which is not only time-consuming and labor-intensive but also prone to errors and omissions, posing significant challenges to subsequent quality traceability and production management. Utility Model Content

[0005] To address the aforementioned technical shortcomings, the purpose of this utility model is to provide an automatic feeding and loading system for sterilizers, achieving automated and precise feeding, and improving operational efficiency and safety.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] An automatic feeding and loading system for a sterilizer includes:

[0008] Sterilization carts are used for loading and transporting materials;

[0009] Sterilization cabinet is used to receive materials transported by sterilization carts and to sterilize the materials.

[0010] Transfer mechanism, used to remove sterilized materials from the sterilization cabinet;

[0011] Sterilization buffer station: After the transfer organization takes the materials out of the sterilization cabinet, it places them on the sterilization buffer station.

[0012] The transport mechanism is used to move materials stored at the sterilization buffer site to the assembly line.

[0013] Preferably, the sterilization cart includes a frame and a storage rack; wheels are installed at the bottom of the frame; a handle is provided on one side of the frame; the storage rack is fixed to the top of the frame; multiple storage compartments are provided on the storage rack; the storage compartments are arranged in an array with equal vertical spacing.

[0014] Preferably, it also includes a communication module and a control cabinet; the sterilization cabinet, transfer mechanism and transport mechanism are connected to the control cabinet through the communication module.

[0015] Preferably, multiple transport mechanisms are configured to transport materials to different assembly lines respectively.

[0016] Preferably, the transport mechanism is a high-speed chain conveyor or an AGV transport vehicle.

[0017] Preferably, the transfer mechanism is a telescopic forklift.

[0018] Preferably, the telescopic fork includes a first motor, a drive sprocket, a chain belt, a driven sprocket, and a telescopic assembly; the telescopic assembly includes a fixed frame, a first shaft, a first drive gear, a first driven gear, a telescopic plate, multiple conveying gears, and multiple transmission gears; the first motor is fixed to the bottom of the fixed frame; the drive sprocket is mounted on the output shaft of the first motor; the first shaft is rotatably mounted on the fixed frame; the driven sprocket and the first drive gear are mounted on the first shaft; the drive sprocket and the driven sprocket are connected by a chain belt; the first driven gear, the conveying gear, and the transmission gears are rotatably mounted on the fixed frame; the conveying gear is located above the first driven gear; multiple conveying gears and transmission gears are alternately spaced in a horizontal plane, and the diameter of the conveying gear is larger than the diameter of the transmission gear; the first driven gear meshes with the first drive gear and one of the conveying gears; the telescopic plate is slidably mounted above the fixed frame; a rack is fixedly mounted at the lower end of the telescopic plate; the rack meshes with the conveying gear.

[0019] Preferably, there are two telescopic components; the first shafts of the two telescopic components are connected by a coupling.

[0020] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0021] This system automates material handling by replacing manual labor with a transport mechanism, eliminating the need for human intervention and reducing time wasted on manual operations. Simultaneously, the transfer mechanism automatically transfers materials into the sterilizer cavity with precise and rapid positioning, effectively solving the time-consuming connection, positioning, and pushing problems inherent in traditional manual feeding, and significantly improving overall operational efficiency.

[0022] The system achieves fully automated operation, and the equipment does not require human intervention. This avoids direct contact between operators and the hot steam overflowing when the sterilizer is opened, fundamentally eliminating the risk of injury to personnel from the hot steam, improving the safety of the operation, and eliminating the need for operators to wear protective equipment, which indirectly improves the smoothness of the operation.

[0023] The multi-line unit can be connected to the same sterilizer, improving the sterilizer's utilization rate and adapting to different production layout requirements. Furthermore, data during the operation can be comprehensively recorded, facilitating subsequent querying, traceability, and management, and providing data support for production process optimization. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of this utility model;

[0025] Figure 2 This is a schematic diagram of the transfer mechanism in this utility model;

[0026] Figure 3 This is a diagram showing the internal structure of the transfer mechanism in this utility model.

[0027] in:

[0028] 1. Sterilization cabinet; 2. Transfer mechanism; 21. Telescopic plate; 22. Rack; 23. Fixing frame; 24. First shaft; 25. Chain belt; 26. Driving sprocket; 27. Driven sprocket; 28. First motor; 29. ​​Conveying gear; 210. Transmission gear; 211. First driven gear; 212. First driving gear; 3. Communication module; 4. Sterilization buffer station; 5. Transport mechanism. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings.

[0030] like Figures 1 to 3 As shown, an automatic feeding and loading system for a sterilizer includes:

[0031] Sterilization carts are used for loading and transporting materials;

[0032] Sterilization cabinet 1 is used to receive materials transported by sterilization carts and to sterilize the materials.

[0033] Transfer mechanism 2 is used to remove sterilized materials from sterilization cabinet 1;

[0034] Sterilization buffer station 4, transfer mechanism 2 takes the material out of sterilization cabinet 1 and places it on sterilization buffer station 4;

[0035] Transport mechanism 5 is used to transport materials stored at sterilization buffer site 4 to the assembly line.

[0036] Furthermore, the sterilization cart includes a frame and a storage rack; wheels are installed at the bottom of the frame; a handle is provided on one side of the frame; the storage rack is fixed to the top of the frame; multiple storage compartments are provided on the storage rack; the storage compartments are arranged in an array with equal vertical spacing.

[0037] Furthermore, it also includes a communication module 3 and a control cabinet; the sterilization cabinet 1, the transfer mechanism 2 and the transport mechanism 5 are connected to the control cabinet through the communication module.

[0038] Furthermore, multiple transport mechanisms 5 are configured to transport materials to different assembly lines respectively.

[0039] Furthermore, the transportation mechanism 5 is a double-speed chain conveyor belt or an AGV transport vehicle.

[0040] Furthermore, the transfer mechanism 2 is a telescopic forklift.

[0041] Furthermore, the telescopic fork includes a first motor 28, a drive sprocket 26, a chain belt 25, a driven sprocket 27, and a telescopic assembly; the telescopic assembly includes a fixed frame 23, a first shaft 24, a first drive gear 212, a first driven gear 211, a telescopic plate 21, multiple conveying gears 29, and multiple transmission gears 210; the first motor 28 is fixed to the bottom of the fixed frame 23; the drive sprocket 26 is mounted on the output shaft of the first motor 28; the first shaft 24 is rotatably mounted on the fixed frame 23; the driven sprocket 27 and the first drive gear 212 are mounted on the first shaft 24; the drive sprocket 26 and the driven sprocket 27 are connected by a chain belt 25; the first driven gear 211, the conveying gear 29, and the transmission gears 210 are rotatably mounted on the fixed frame 23; the conveying gear 29 is located above the first driven gear 211; the multiple conveying gears 29 and the transmission gears 210... Wheels 210 are alternately spaced in the horizontal plane. The diameter of the conveying gear 29 is larger than the diameter of the transmission gear 210. The first driven gear 211 meshes with the first driving gear 212 and one of the conveying gears 29. The telescopic plate 21 is slidably mounted above the fixed frame 23. A rack 22 is fixedly mounted at the lower end of the telescopic plate 21. The rack 22 meshes with the conveying gear 29. After the first motor 28 starts, it drives the first driving gear 212 to rotate. The first driving gear 212 drives the first driven gear 211 to rotate, which in turn drives the conveying gear 29 to rotate. Through the meshing transmission of the conveying gear 29 and the rack 22, the telescopic plate 21 makes reciprocating telescopic movements on the fixed frame 23, which facilitates the conveying of materials on the sterilization cabinet 1 to the sterilization buffer station 4. The transmission gear 210 is used to ensure that multiple conveying gears 29 rotate synchronously, so that the rack 22 slides smoothly on the fixed frame 23.

[0042] Furthermore, there are two telescopic components; the first shafts 24 of the two telescopic components are connected by a coupling.

[0043] Example 1: Automatic feeding system for a fixed production line based on a double-speed chain conveyor belt

[0044] Application scenario: Suitable for medical device sterilization workshops with fixed production processes and stable material transportation paths, requiring connection to 2-3 assembly lines, and demanding automated material feeding with high cycle time and low error.

[0045] System Composition

[0046] Sterilization cart: It adopts a frame (with silent wheels at the bottom) + top storage rack structure. The storage rack has 6 storage compartments with equal vertical spacing (30cm) (size 40cm×30cm×25cm), which are compatible with standard sterilization baskets (for loading surgical instruments). A handle is provided on one side of the frame for easy manual assistance in initial loading.

[0047] Sterilization cabinet 1: 500L capacity, equipped with an automatic door opening mechanism (electromagnetic drive), 1.5m away from sterilization buffer station 4, and a position sensor is installed on the inside of the cabinet door (for detecting the alignment of transfer mechanism 2).

[0048] Relay mechanism 2: The telescopic fork with double telescopic components (as described in document 2) is fixed on the track between the sterilizer 1 and the buffer station (it can move ±50cm in the direction perpendicular to the sterilizer 1). The telescopic plate 21 of a single telescopic component has a stroke of 80cm and a load capacity of 50kg.

[0049] Sterilization buffer station 4: It is equipped with two buffer slots (the size of which matches the storage compartment of the sterilization cart), and the surface is embedded with an RFID reader (to read the information of the sterilization basket tag). It is aligned with the transfer mechanism 2 and the transportation mechanism 5 through infrared sensors.

[0050] Transportation mechanism 5: Two parallel double-speed chain conveyor belts (speed adjustable, 0.5-1.5m / s) are connected to assembly line 1 and assembly line 2 respectively. The sides of the conveyor belts are equipped with guards (10cm high) to prevent materials from slipping. The end of the conveyor belt is equipped with a position sensor at the connection point with the assembly line.

[0051] Control and Communication: Equipped with a control cabinet (including a PLC controller), it connects to the sterilization cabinet 1, transfer mechanism 2, double-speed conveyor belt and buffer station via communication module 3 (using industrial Ethernet) to achieve real-time signal interaction.

[0052] Workflow

[0053] Material loading: The medical devices to be sterilized (such as surgical forceps and syringes) are manually placed into the sterilization basket, and then the sterilization basket is placed layer by layer into the storage compartment of the sterilization cart and pushed to the loading area at the entrance of sterilization cabinet 1 (triggering the entrance sensor).

[0054] Sterilizer 1 docking: After receiving the loading signal, the control cabinet triggers the opening of the sterilizer 1 door through the communication module 3 (takes 3 seconds), and at the same time controls the transfer mechanism 2 to move to the door of the sterilizer 1 for alignment (error ≤ 2mm).

[0055] Material transfer: The telescopic forks of the transfer mechanism 2 are activated: the first motor 28 drives the drive sprocket 26 to rotate, which drives the driven sprocket 27 and the first shaft 24 to rotate through the chain belt 25. The first drive gear 212 meshes with the first driven gear 211, which in turn drives the conveying gear 29 to rotate. The rack 22 at the lower end of the telescopic plate 21 meshes with the conveying gear 29, so that the telescopic plate 21 extends into the sterilization cabinet 1 (stroke 60cm), lifts and moves the sterilization basket in the uppermost storage compartment of the sterilization cart out, and after retraction, places it in the first buffer position of the sterilization buffer station 4 (the RFID reader synchronously records the material ID and time).

[0056] Transport to the assembly line: After receiving the "material ready" signal from the buffer station, the double-speed chain conveyor belt starts and transports the sterilization basket (after being processed by sterilization cabinet 1) from buffer position 1 to the connection point of assembly line 1. After it arrives, the conveyor belt stops and the assembly line robot picks up the material (triggers the "material picked up" feedback signal).

[0057] Cyclic operation: Repeat steps 3-4 to process the materials in the remaining storage compartments of the sterilization cart in turn until all materials have been sterilized and transferred. The control cabinet records the entire process data (such as sterilization time, transportation path, abnormal alarms, etc.).

[0058] Beneficial effects

[0059] The use of a double-speed chain conveyor belt enables high-speed transportation along a fixed path, with a cycle time of up to 30 seconds per basket, which is 40% more efficient than traditional manual loading.

[0060] The telescopic forks have a positioning error of ≤2mm, solving the problem of inaccurate positioning in traditional manual docking.

[0061] The sterilization cabinet 1 is completely contactless with personnel (zero exposure to warm steam), improving operational safety by 100%.

[0062] Example 2: Automated Feeding System for Flexible Production Line Based on AGV

[0063] Application scenarios: Suitable for biological agent workshops with multiple varieties and small batch production, requiring connection to more than 5 flexibly laid-out assembly lines, and requiring that the transportation route can be dynamically adjusted to adapt to temporary additional orders or production line switching.

[0064] System Composition

[0065] Sterilization cart: Lightweight design (the frame is made of aluminum alloy), with 4 storage compartments (compatible with 500ml biological reagent bottles), and a QR code on the bottom of the frame (for AGV identification and positioning).

[0066] Sterilization cabinet 1: Miniature sterilization cabinet 1 (300L capacity), the cabinet door is equipped with a mechanical lock and communication interface, supporting remote control of opening and closing the door.

[0067] Reprinting Agency 2: Simplified telescopic forklift (single telescopic component, telescopic plate 21 with a stroke of 50cm), fixed next to sterilizer 1, with a docking height of 70cm with the AGV (matching the AGV cargo platform).

[0068] Sterilization buffer site 4: Three mobile buffer stations (with braked casters) are set up in a distributed manner. Each buffer station has two buffer positions and a built-in Bluetooth positioning module (to communicate with the AGV).

[0069] Transportation Unit 5: 3 AGV transport vehicles (load capacity 50kg, navigation method: laser SLAM), equipped with a lifting mechanism (which can raise the cargo platform to the height of the buffer station), and support dynamic path planning (scheduled via control cabinet).

[0070] Control and Communication: The control cabinet is equipped with an MES system, which communicates with the AGV, sterilizer 1, and transfer mechanism 2 via Wi-Fi to update the material transportation task list in real time.

[0071] Workflow

[0072] Task allocation: The MES system receives the "materials to be sterilized" (e.g., 10 bottles of biological agents) from assembly line 3 and generates a transportation task: AGV1 picks up the sterilization cart carrying the materials from the raw material area and transports it to the entrance of sterilization cabinet 1.

[0073] Sterilization and transfer: After the sterilization process is completed, the sterilization cabinet 1 sends a "sterilization complete" signal to the control cabinet through the communication module 3; the telescopic plate 21 of the transfer mechanism 2 extends to transfer the sterilized material from the sterilization cabinet 1 to the No. 2 buffer station (the buffer station sends its position coordinates to the AGV1 via Bluetooth).

[0074] AGV transfer: After receiving the location signal of the buffer station, AGV1 plans the optimal path (avoiding the transportation route of AGV2), travels to the side of buffer station No. 2, raises the lifting mechanism to 70cm, and moves the material from the buffer station to its own cargo platform, and scans the code to record the material information (such as sterilization temperature and time).

[0075] Flexible docking: AGV1 dynamically adjusts its path to assembly line 3 according to the instructions of the MES system (the original path is occupied due to temporary additional orders, so it automatically switches to the backup channel). After arriving, the lifting mechanism lowers and delivers the materials to the assembly line docking station. After completing the task, it returns to the standby area.

[0076] Beneficial effects

[0077] AGVs' flexible transportation adapts to dynamic production line layouts, with a path adjustment response time of ≤10 seconds, improving flexibility by 60% compared to fixed conveyor belts;

[0078] Distributed caching sites reduce device wait time, increasing the utilization rate of sterilizer 1 from 60% to 85%;

[0079] The MES system records material flow data throughout the entire process, allowing traceability to the sterilization process of a single bottle of formulation, thus meeting GMP compliance requirements.

[0080] Example 3: Intelligent Traceability Feeding System with Multi-Line Collaboration

[0081] Application scenario: Suitable for large-scale integrated medical supplies production bases, which need to connect to 5 assembly lines (including 2 double-speed chain lines + 3 AGV lines) and share 1 large sterilization cabinet. The requirement is to realize multi-line priority scheduling and full-process data traceability.

[0082] System Composition

[0083] Core equipment:

[0084] Sterilization cabinet 1: 1000L capacity, equipped with temperature / pressure sensors (data is uploaded to the control cabinet in real time);

[0085] Reprinted from Organization 2: Double telescopic forklift with 100kg load capacity, equipped with a vision positioning camera (to assist in alignment with the sterilization trolley);

[0086] Transportation Unit 5: 2 double-speed chain conveyor belts (connecting to assembly lines 1 and 2) + 3 AGVs (connecting to assembly lines 3, 4, and 5);

[0087] Sterilization Cache Site 4: 4 fixed cache slots (with electronic label printer, automatically printing material traceability codes).

[0088] Control and traceability system:

[0089] The control cabinet has a built-in scheduling algorithm that supports the allocation of materials according to assembly line priority (e.g., assembly line 1 is the emergency supplies line, with the highest priority).

[0090] Data recording module: Stores information such as material ID, sterilization parameters (temperature 134℃, time 30min), transportation route, and operator (initial loading), which can be queried by scanning a code or through the backend.

[0091] Workflow

[0092] Multi-line task scheduling: The control cabinet simultaneously receives material feeding requests from assembly line 1 (emergency instruments) and assembly line 3 (consumables), and schedules them according to priority: materials from assembly line 1 are processed first.

[0093] Collaborative feeding:

[0094] Reprinting agency 2 uses a visual camera to identify the location of the sterilization cart storage compartment, accurately retrieves the emergency instrument sterilization basket, prints a traceability code at the cache station (affixed to the basket), and quickly delivers it to assembly line 1 via a double-speed conveyor belt (time ≤ 2 minutes);

[0095] Then, the routine consumables for assembly line 3 are processed: AGV3 picks up materials from the buffer station and transports them along the planned route, avoiding AGV4 which is feeding materials to assembly line 4 via communication module 3.

[0096] Abnormal Handling: If assembly line 2 experiences a sudden material shortage (triggers an emergency signal), the control cabinet will suspend the AGV3 task of assembly line 3 and prioritize scheduling the double-speed chain conveyor to replenish materials for assembly line 2. The task switching time is ≤15 seconds.

[0097] Traceability Inquiry: When a batch of materials needs to be traced, scanning the traceability code can display the following full-process data: sterilization start time (2024-06-10 08:30), sterilization cabinet number 1 (S-005), transport AGV number (A-003), arrival time at the assembly line (08:45).

Claims

1. An automatic feeding and loading system for a sterilizer, characterized in that, include: Sterilization carts are used for loading and transporting materials; Sterilization cabinet (1) is used to receive materials transported by sterilization carts and to sterilize the materials. Transfer mechanism (2) is used to remove sterilized materials from sterilization cabinet (1); Sterilization buffer station (4), transfer mechanism (2) takes the material out of sterilization cabinet (1) and places it on sterilization buffer station (4); The transport mechanism (5) is used to transport materials stored at the sterilization buffer site (4) to the assembly line.

2. The automatic feeding and loading system for sterilizers as described in claim 1, characterized in that, The sterilization cart includes a frame and a storage rack; wheels are installed at the bottom of the frame; a handle is provided on one side of the frame; the storage rack is fixed to the top of the frame; multiple storage compartments are provided on the storage rack; the storage compartments are arranged in an array with equal vertical spacing.

3. The automatic feeding and loading system for sterilizers as described in claim 1, characterized in that, It also includes a communication module (3) and a control cabinet; the sterilization cabinet (1), the transfer mechanism (2) and the transport mechanism (5) are connected to the control cabinet through the communication module.

4. The automatic feeding and loading system for sterilizers as described in claim 1, characterized in that, The transport mechanism (5) is configured in multiple ways to transport materials to different assembly lines.

5. The automatic feeding and loading system for sterilizers as described in any one of claims 1 to 4, characterized in that, The transport mechanism (5) is a double-speed chain conveyor belt or an AGV transport vehicle.

6. The automatic feeding and loading system for sterilizers as described in any one of claims 1 to 4, characterized in that, The transfer mechanism (2) is a telescopic fork.

7. The automatic feeding and loading system for sterilizers as described in claim 6, characterized in that, The telescopic fork includes a first motor (28), a drive sprocket (26), a chain (25), a driven sprocket (27), and a telescopic assembly; the telescopic assembly includes a fixed frame (23), a first shaft (24), a first drive gear (212), a first driven gear (211), a telescopic plate (21), multiple conveying gears (29), and multiple transmission gears (210); the first motor (28) is fixed to the bottom of the fixed frame (23); the drive sprocket (26) is mounted on the output shaft of the first motor (28); the first shaft (24) is rotatably mounted on the fixed frame (23); the driven sprocket (27) and the first drive gear (212) are mounted on the first shaft (24); the drive sprocket (26) and the driven sprocket (27) are connected by a single drive sprocket. The transmission is connected via a chain belt (25); the first driven gear (211), the conveying gear (29), and the transmission gear (210) are rotatably mounted on the fixed frame (23); the conveying gear (29) is located above the first driven gear (211); multiple conveying gears (29) and transmission gears (210) are alternately spaced in the horizontal plane, and the diameter of the conveying gear (29) is larger than the diameter of the transmission gear (210); the first driven gear (211) meshes with the first driving gear (212) and one of the conveying gears (29) for transmission; the telescopic plate (21) is slidably mounted above the fixed frame (23); a rack (22) is fixedly provided at the lower end of the telescopic plate (21); the rack (22) meshes with the conveying gear (29) for transmission.

8. The automatic feeding and loading system for sterilizers as described in claim 7, characterized in that, The telescopic assembly is configured in two parts; the first shaft (24) of the two telescopic assemblies is connected by a coupling.

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