Device and method for filling containers and plant for processing containers

Abstract

The present invention relates to a device (134) for filling containers (102) with a particularly liquid product in a filling process, in particular a pharmaceutical container (102) with a pharmaceutical product, comprising a filling needle device (136) which comprises or forms a filling needle (158) for dispensing the product and which can be inserted into the container (102) via an insertion opening (116), and a sensor device (138) by means of which a fill level of the product in the container (102) can be determined, wherein the sensor device (138) is designed as an electrical, in particular as a capacitive and / or as a conductive, sensor device (138) and comprises a first electrode (178) and a second electrode (180) as well as an evaluation unit (198) coupled to the electrodes (178, 180), wherein at least one of the electrodes (178, 180) is in the container (102) can be inserted,wherein, during filling of the container (102), a measurement signal (218) indicative of the fill level of the product in the container (102) can be detected or determined by the evaluation unit (198), and wherein a stop signal can be provided to a dosing device (140) to terminate the filling process. Furthermore, the invention relates to a system for processing containers and a method for filling containers.

Description

[0001] The present invention relates to a device for filling containers with a product, in particular a liquid, in a filling process, in particular a pharmaceutical container with a pharmaceutical product, comprising a filling needle device which includes or forms a filling needle for dispensing the product and which can be inserted into the container via an insertion opening, and a sensor device by means of which a fill level of the product in the container can be determined.

[0002] In this context, a “pharmaceutical product” can also be understood to mean a “medical product”.

[0003] Furthermore, the present invention relates to a method for filling a container with a product using a device of the type described above.

[0004] Furthermore, the present invention relates to a system for processing containers, in particular pharmaceutical containers, with at least one processing station for processing the containers, which includes a filling station comprising a device of the type described above.

[0005] When processing containers in such a system, it is desirable to standardize and perform the filling process as precisely as possible, both for the intended use of the containers and for the reliable operation of the dispensing device in which they are used. It is known, for example, that the quantity of product dispensed is determined based on its mass. For this purpose, the mass can be determined by the difference between the gross weight of the filled container and the tare weight of the empty container. For other applications, however, it may be advantageous to determine the fill level of the product in the container, and in particular to determine it as precisely as possible. It is conceivable that checking the fill level could be combined with checking the mass. However, this is not strictly necessary.

[0006] Different fill levels with the same product mass can occur, for example, due to tolerances in the containers and / or the closure elements used. The present invention relates to a device, a method, and a system in which the fill level of the product in a container can be determined as precisely as possible.

[0007] Monitoring the fill level proves advantageous, for example, in applications where containers are used in dispensing devices. These dispensing devices can be insulin pens, for instance, where reliable mechanical function and the delivery of the correct dose of product must be ensured. These devices typically utilize cartridges that have a crimped cap on one end and a stopper on the other. The stopper acts as a stop to define the correct position within the insulin pen. Therefore, it is desirable for the stopper to be positioned with the highest possible accuracy at this defined position during the handling of the containers.

[0008] In the prior art, there are conventional solutions where the cartridges are filled with a pre-installed stopper element via the opening to which the crimp cap will later be attached. Filling cartridges via the narrow opening opposite the stopper element has proven reliable in practice. However, monitoring the fill level is complex. Furthermore, due to equipment limitations, it is not possible to fill the cartridges nested within the common carrier with sufficient accuracy. This is because the previously used optical inspection near the narrow opening is not feasible for containers within the carrier due to space constraints, and the requirements for cleanability and sterilizability cannot be met. Therefore, measurement must be taken remotely with reduced accuracy.

[0009] Furthermore, there are conventional devices in which a pre-crimped cartridge is filled through the opening into which the stopper element is later inserted. However, it is essential to ensure that the fill level is precisely maintained so that the stopper element can be placed in the correct position. DE 10 2012 207 587 A1 describes a device for filling a cartridge. An optical sensor, positioned at a distance from the cartridge, determines the fill level of the product within the cartridge.

[0010] An optical sensor device is also used in a device for filling cartridges, as described in WO 2023 / 174645 A1. In this device, several cartridges are held in a common carrier, configured as a nest. The cartridges are already crimped and positioned with the crimped end at the bottom of the carrier. Therefore, the cartridge can only be filled from the end where the stopper element will later be inserted. The optical sensor device is positioned laterally next to the carrier, resulting in a considerable distance from the cartridges. This large distance proves to be a disadvantage because the measurement is not taken at the filling point.Component tolerances, insufficient positioning of the sensor device, interfering factors such as vibrations of the apparatus during measurement and / or a flow of gas in the working chamber (e.g., laminar flow) can distort the result.

[0011] If the fill level is determined solely by the volume filled, tolerances mean that the accuracy required in practice, for example, approximately 0.5 mm to 0.6 mm of fill level, as revealed by visual inspection, cannot be achieved frequently enough. This undesirably results in a high reject rate of already filled and sealed containers, for example, approximately 10% to 15%.

[0012] CN 102 944 286 A describes a device with which the fill level of a product in a container can be determined capacitively.

[0013] However, the present invention is not limited to applications involving containers in the form of cartridges. Furthermore, the present invention is not limited to use with systems in which containers can be processed in a common carrier. The above statements serve only as examples to illustrate considerations that may underlie the present invention.

[0014] Position and orientation specifications, such as "bottom," "top," or the like, refer here to the intended use of the device and the system, as well as to the intended execution of the procedure. It is intended that the filling needle is inserted from above through the insertion opening into the container in order to dispense the product.

[0015] The object of the present invention is to provide a generic device with which a higher accuracy in determining the fill level of the product in the container can be achieved, preferably with a structurally simple design, particularly with regard to the subsequent insertion of a stopper element in or on the container.

[0016] This problem is solved according to the invention in a device of the type mentioned at the outset by the fact that the sensor device is designed as an electrical, in particular as a capacitive and / or as a conductive, sensor device and comprises a first electrode and a second electrode as well as an evaluation unit coupled to the electrodes, wherein at least one of the electrodes can be inserted into the container, wherein a measurement signal can be detected or determined by the evaluation unit when the container is filled, which is indicative of the fill level of the product in the container, and wherein a stop signal can be provided directly or indirectly to a dosing device to end the filling process.

[0017] In the device according to the invention, an electrical sensor is used instead of the optical sensor devices known in the prior art. An electrostatic and / or an electrodynamic mode of operation is particularly conceivable. The sensor can be designed, in particular, as a capacitive and / or a conductive sensor. The sensor comprises a first electrode and a second electrode. At least one electrode can be inserted into the container. When the container is filled, the electrical properties of the filled container change due to the product. During filling with the product, this change in properties can be detected via the electrodes and determined by the evaluation unit. The evaluation unit can, in particular, acquire or determine a measurement signal that is indicative of the fill level.Once the desired fill level is reached, a stop signal can be sent directly or indirectly, e.g., via a control unit, to a dosing device, which then feeds the product to the filling needle. As practical experience shows, inserting at least one electrode into the container ensures particularly reliable monitoring of the correct fill level. Measuring during filling eliminates the need for a separate measurement process and the associated transport of the container.

[0018] A particular advantage of the present invention is that high measurement accuracy can be achieved while maintaining a simple design. The invention is suitable not only for individual processing of containers, containers in a circulating transport system, or in a rack transport system, but preferably also for filling containers in a common carrier (for example, in a nest). In particular, it allows for filling cartridges via the end into which the stopper element is inserted. As practical experience shows, the required installation space for the at least one electrode within the container can be kept so small that the filling needle and at least one electrode can be inserted into the cartridge.

[0019] The fill level can be determined, for example, relative to a reference position, or it can be ensured that the container is filled to a target fill level that is a predetermined distance from a reference position. This reference position can be defined, for example, by the position of the container. This could be, for instance, the section where the container is attached or supported by a support element or plunger. For example, when filling cartridges, a pre-crimped end of the cartridge could be chosen as the reference position, so that, with the correct target fill level, a target position of the stopper element can be maintained if this target position is important for the intended use (as explained above using the example of insulin pens).

[0020] It is conceivable, in particular, that the at least one electrode in the container can be positioned or aligned relative to the reference position. For example, the electrode can be positioned using an adjustment device, the adjustment device being calibrated relative to the reference position.

[0021] Furthermore, it is advantageous that a measurement within the container itself is more accurate than one performed by sensor devices located outside the container, as described above. For example, if the fill level fluctuates due to movement of the container or the surface tension of a liquid product, optical sensor devices will provide inaccurate fill level readings. This can be avoided with the invention. In addition, the measurement is performed directly on the product inside the container. The need to position the sensor device at a distance from the actual measuring position is eliminated. Potential sources of interference, such as inadequate positioning of the sensor device, influences from vibrations, or gas flow in the working chamber, are thereby minimized, resulting in a more precise measurement.

[0022] In this case, the dosing device can be or include a pumping device. For example, the use of a peristaltic pump is conceivable.

[0023] The evaluation unit can be part of a control unit of the device or a control unit of the plant. Conversely, it can be provided that the evaluation unit forms the control unit of the device or the control unit of the plant.

[0024] Furthermore, the present invention allows hygienic requirements to be met during the processing of the containers if the containers are arranged in a common carrier. For example, sensor devices cannot be positioned near the insertion opening of containers in a common carrier because they are located above the opened containers, for example in the gas stream in the filling area, so that hygienic requirements cannot be met. However, these requirements can be met by using the filling needle device of the apparatus according to the invention.

[0025] To insert the filling needle and the at least one electrode into the container, at least one adjustment device can be provided. Separate adjustment devices are conceivable, which can be operated synchronously for synchronous movement of the at least one electrode and the filling needle. Alternatively, it is conceivable that one adjustment device is used to move the at least one electrode and the filling needle together.

[0026] It is advantageous if at least one electrode on the filling needle assembly is held or arranged in a defined, and in particular unchanging, spatial relationship to the filling needle and can be inserted into the container with the filling needle, and / or if an electrode is formed by the filling needle itself. This allows for a simple design with a preferably compact form. At least one electrode can be inserted into the container together with the filling needle. For this purpose, a common adjustment mechanism can be used, for example, and separate adjustment mechanisms can be omitted. The filling needle itself can, for example, form the first electrode. This eliminates the need for a separate pair of electrodes.Alternatively or additionally, the second electrode can be held or arranged in a defined spatial relationship to the filling needle on the filling needle device, so that it can be located in the container in a defined target position relative to the filling needle.

[0027] In practice, for example, it has been shown that when using the filling needle as an electrode, significant changes in the measurement signal can be observed if the product level reaches the filling needle. These significant changes can be reliably detected by the evaluation unit to maintain the required accuracy in determining the fill level.

[0028] It can be advantageous if both electrodes can be inserted into the container.

[0029] It can be advantageous, for example, if the first and second electrodes on the filling needle device are held or arranged in a defined, and in particular unchanging, spatial relationship to the filling needle. This allows both electrodes to be inserted into the container to achieve the highest possible measurement accuracy.

[0030] In one embodiment of the invention, an electrode may be formed by a component of the container to be filled, in particular by a closure element located on the side of the container opposite the insertion opening. For example, when filling crimped cartridges, the crimp cap could be used as a counter electrode to an electrode (e.g., the filling needle) located in the container.

[0031] It is conceivable that an electrode is formed separately from the container. For example, an electrode could be positioned laterally next to the container, or it could be a sleeve or tube located outside the container and at least partially surrounding it. The container could, for instance, be inserted into the sleeve or tube.

[0032] In a structurally simple embodiment, the first electrode can be a tube or comprise a tube. The tube can, in particular, be the filling needle or a component thereof. Furthermore, the second electrode is advantageously a sleeve or comprises a sleeve that surrounds the tube. This ensures a structurally simple design with a compact form. If the tube is the filling needle or a part thereof, the sleeve preferably also serves as a needle guard. The filling needle assembly thus has a more robust design.

[0033] It may be provided that the filling needle or tube extends beyond the sleeve, relative to the insertion direction into the container to be filled. In this embodiment, the filling needle or tube is therefore closer to the product level than the sleeve. Such a design can prove advantageous, for example, for measurements on liquids with relatively low conductivity, such as water or aqueous solutions.

[0034] Alternatively, the sleeve can be designed to extend beyond the filling needle or tube, relative to the insertion direction into the container. In this case, the sleeve is closer to the fill level than the filling needle or tube. Practical experience has shown that such a design is advantageous, for example, for liquids with relatively high conductivity and can be beneficial for measurements of insulin for insulin cartridges. Furthermore, practical experience has shown that such a design can be more universally applicable than the embodiment described in the preceding paragraph. For example, this design can also be used for water or aqueous liquids.

[0035] The sleeve can have or form at least one point at its end, on the side facing the product when inserted. A relatively high local field strength can be achieved via this point, for example, for capacitive measurements. This can prove advantageous for precise measurements. Furthermore, droplets of a liquid product can detach more easily from the sleeve if it is immersed in the liquid during filling. This can be the case, for example, in the embodiment mentioned above, where the sleeve extends beyond the filling needle or tube.

[0036] Two opposing points can be provided, between which preferably concave recesses, for example in a U-shape, are formed on the sleeve.

[0037] The filling needle device preferably comprises an electrical insulating element arranged between the tube and the sleeve, extending at least partially along a portion of the tube and sleeve. Accordingly, in a preferred embodiment, the insulating element can be arranged between the filling needle, if it forms an electrode, and the sleeve. For example, the insulating element is sleeve-shaped. The insulating element can, for instance, extend approximately over at least half the length of the filling needle and the sleeve.

[0038] For example, the insulating element extends to or close to the respective lower end of the pipe and sleeve that faces the product.

[0039] The insulating element can also perform mechanical functions of the filling needle device. For example, the insulating element comprises a mounting flange and rests directly or indirectly against a holding body of the filling needle device via this flange. The insulating element can form a mounting element on which the filling needle rests with a base body that is fluid-connected to the tube. In this way, the filling needle can be reliably held against the holding body. It is conceivable that the insulating element rests indirectly against the holding body, for example, via a sleeve-shaped protective element that surrounds the sleeve and the tube. The base body of the filling needle can, for example, be designed in a bushing-like shape, with the tube inserted into the base body. A connection element for attaching a supply line, in particular a flexible hose, can be formed on the base body.

[0040] The retaining body can, for example, include or form a concave recess into which the base body is inserted. The base body can form a mounting flange and rest against an edge of the recess via this flange.

[0041] Alternatively or additionally, a concave recess for the aforementioned protective element can be arranged or formed on the mounting body. The protective element can, for example, comprise a mounting flange that rests against an edge of the recess, with the insulating element bearing against the mounting flange on the protective element.

[0042] The insulating element may be designed to contact the pipe on an inner circumferential surface and / or the sleeve on an outer circumferential surface, and / or to incorporate spacers on the insulating element, creating at least one gap between the insulating element and the sleeve and / or between the insulating element and the pipe. For example, the insulating element may rest against the pipe on its inner circumferential surface and be supported by the spacers on the sleeve. Alternatively, the insulating element may rest against the sleeve on its outer circumferential surface and be supported by the spacers on the pipe. A gas, in particular compressed air or nitrogen, may flow through the at least one gap between the insulating element and the sleeve and / or between the insulating element and the pipe.By applying gas, for example, drops of liquid product that may adhere to the sleeve and / or tube as a result of the filling needle device being immersed in the product can be blown off. This serves, firstly, to improve measurement of the fill level. Adhering liquid is preferably blown off and thus cannot drip outside the container. Alternatively, the filling needle device can be moved away from the container to a cleaning position via a transport device, or can assume a cleaning position to blow off any adhering liquid.

[0043] During the filling process, in one embodiment of the invention, a protective gas such as nitrogen can be introduced into the container to protect the product from oxidation. The protective gas can, for example, be supplied through the aforementioned gap.

[0044] The filling needle device can comprise a holding body on which the filling needle and the sleeve are held, and a connection element for a supply line arranged on the holding body, the connection element being in flow communication with the at least one cavity. A gas supply device can be arranged on the connection element via the supply line, thereby supplying the at least one cavity with gas.

[0045] To provide the flow connection, a flow channel can be formed in the retaining body, for example, which opens directly or indirectly into the at least one cavity for pressurizing the at least one cavity with gas. For example, the flow channel opens at the edge of a receptacle. A protective element for the sleeve can have a through-opening. The sleeve itself can also have a through-opening. The through-openings can be aligned. Gas flows, for example, through the retaining body, the protective element, and the sleeve into a cavity between the sleeve and the insulating element.

[0046] In a preferred embodiment, the filling needle device can comprise two or more filling needles and preferably a holding body to which the filling needles are attached, allowing two or more containers to be filled via the filling needles. Accordingly, the filling needle device can be configured with multiple needles. Each container can be filled via a filling needle. Not only is a two-needle configuration conceivable, but even more filling needles can be present. For example, it can be provided that there are enough filling needles to fill at least one row of a common container carrier, preferably two rows.

[0047] It is understood that the filling needles are advantageously designed identically. The same applies to the components of the device mentioned above in connection with the filling needle, for example, the sleeve, the insulating element, the protective element, the base body, or the tube. The aforementioned components are preferably designed identically or at least functionally equivalent and can form a filling unit. The receptacles can be identical.

[0048] The two or more filling needles can be assigned a common connection element for supplying gas. A flow channel in the base body can branch to allow gas to flow to a specific intermediate space.

[0049] Advantageously, the sensor device comprises two or more first electrodes and second electrodes, with each filling needle being assigned a first electrode and a second electrode. During the filling of the respective container, the evaluation unit can detect or determine a measurement signal that is indicative of the product level in the respective container. A stop signal can be provided, directly or indirectly, to a dosing device to terminate the filling process. In a multi-position configuration, it is advantageously possible to determine the fill level in the containers individually. This is advantageous, for example, due to component tolerances and / or tolerances in the positioning of the filling needle device and / or the containers via at least one adjustment mechanism.

[0050] Advantageously, each filling needle is assigned a dosing device, so that the supply of product to each filling needle can be started and / or stopped separately and thus dosed separately.

[0051] The aforementioned retaining body can comprise or form a respective holding area to which a filling needle is held. The holding area includes, for example, at least one receptacle for the base body and / or for the protective element.

[0052] A holding area is formed, for example, on a projection of a housing of the holding body, with the filling needle arranged on the side of the projection facing away from the housing, and with a recess formed laterally next to the projection in which the other filling needle is arranged. This allows, for example, a staggered arrangement of the filling needles on the holding body. Such a staggered arrangement can be used, for example, for filling containers within a common carrier (e.g., a nest) that are positioned in successive rows of the carrier. Containers in successive rows are usually arranged in a staggered arrangement relative to each other.

[0053] In a structurally simple embodiment of the invention, the filling needle device may comprise two electrodes that are formed separately from the filling needle and are fixed to the filling needle or to a sleeve surrounding the filling needle by means of at least one retaining element. For example, separate electrodes are fixed to the outside of the filling needle or the sleeve.

[0054] The electrodes may be printed as electrical conductors onto a preferably flexible holding element. This holding element can be attached, for example, to the outside of the filling needle or to a sleeve surrounding the filling needle.

[0055] Alternatively, the electrodes can be printed onto the filling needle device as conductive traces, for example on the sleeve or the tube.

[0056] For example, 3D printing can be used to print the conductive traces.

[0057] The sensor device may be designed to continuously detect or determine a measurement signal.

[0058] Alternatively, the sensor device can be used to record or determine the measurement signal at time intervals.

[0059] As already mentioned, the sensor device is electrically designed, in particular capacitive and / or conductive.

[0060] It is conceivable that the evaluation unit for a capacitive and / or conductive measurement provides an electrical voltage between the first electrode and the second electrode, and that as a result of a changing distance between the at least one electrode in the container and the other electrode, a change in voltage and / or a change in current flow between the electrodes can be detected.

[0061] For example, an alternating voltage is applied across the electrodes. The voltage might be, for instance, 10 VAC, with a frequency of approximately 10 kHz to 200 kHz. An electric field can change as a result of the product's level, particularly that of a liquid. In practice, during a capacitive measurement, a significant change in the electric field is observed when an electrode contacts or is immersed in the product. The corresponding measurement signal can be reliably detected by the evaluation unit.

[0062] A change in the measurement signal can, for example, manifest as a significant increase in the measurement signal. Conversely, a change in the measurement signal can manifest as a significant decrease in the measurement signal.

[0063] It goes without saying that the sensor system can and ideally should be calibrated depending on the product being filled and / or the container. This ensures that suitable measurement signals are generated for the most reliable possible determination of the fill level.

[0064] The design may stipulate that the filling needle or electrode is immersed in or touches the product. Alternatively, it may stipulate that neither contact nor immersion is required.

[0065] During operation of the device, the filling needle can, for example, be inserted into the container via an adjustment mechanism. An adjustment range can be preset so that the target fill level is reached when the filling needle or tube touches or enters the product. Feedback can be provided if the measurement signal indicates that the desired target fill level has not been reached when the filling needle or tube touches or enters the product.

[0066] The inventive system for processing containers, in particular pharmaceutical containers, comprises at least one processing station for processing the containers, which includes a filling station, wherein the filling station comprises a dosing device and a device of the type described above, a control device coupled to the dosing device and the sensor device, and at least one adjustment device for providing a relative movement between at least one container and the filling needle device and / or between at least one container and at least one electrode, wherein, during operation of the system, the filling needle and the at least one electrode are inserted into the container via the insertion opening, a filling process is started in which the dosing device is activated to fill the container with the product, and wherein the dosing device is deactivated to end the filling process.when the fill level of the product in the container reaches a predetermined target fill level.

[0067] “Coupling of the sensor device with the control device” can in this case include the fact that the evaluation unit of the sensor device is part of the control device or that the evaluation unit forms the control device.

[0068] The advantages and effects already mentioned in connection with the explanation of the device according to the invention can also be achieved with the system according to the invention. Reference is made to the preceding explanations. Advantageous embodiments of the system according to the invention result from advantageous embodiments of the device according to the invention. Reference is made to the preceding explanations.

[0069] If the filling needle device, in a multi-position configuration, comprises two or more filling needles, the system advantageously includes two or more metering units, with each filling needle having its own metering unit. This allows for individual filling via each filling needle. The fill level of each container can preferably be determined separately via the evaluation unit.

[0070] It is conceivable that the filling needle device for filling the container is stationary and that at least one container is moved via the adjustment device.

[0071] Alternatively, it can be provided that at least one container is stationary, with the filling needle device being moved via the adjustment device.

[0072] Alternatively, it is conceivable that at least one container as well as the filling needle device are moved.

[0073] The at least one adjusting device can, for example, be or include a lifting device comprising a lifting element by which the container can be lifted in the direction of the filling needle device. The lifting element is, for example, a plunger with which the container is subjected to a force from below in the direction of the filling needle device.

[0074] The at least one adjustment device can be or include a lifting device by which the filling needle device can be lowered towards the container.

[0075] As previously mentioned, a separate adjustment device may be used for the at least one electrode, which may be or include a lifting mechanism. It can be advantageous if at least one electrode is held or arranged on the filling needle assembly, or if the filling needle itself forms an electrode. In this way, one adjustment device can be eliminated.

[0076] For example, for nested containers, it is advantageous if the system includes a handling device for handling, especially transporting, a carrier for multiple containers, and if at least one container can be lifted, at least partially, from the carrier towards the filling needle device via the lifting device. In this way, containers can be processed within the carrier. These containers are, for example, crimped cartridges that are filled via the insertion opening into which the stopper element is subsequently inserted. It is particularly conceivable that two or more containers can be filled simultaneously. For this purpose, the filling needle device can have several filling needles, as already described. Advantageously, filling in rows is possible and / or filling containers in two or more rows.

[0077] The system can be free of an optical sensor device for monitoring the fill level, at least at the filling station.

[0078] The containers can be pre-crimped carpules, with a pre-crimped end of the carpule arranged at the bottom of the carrier and the insertion opening for inserting a plug element provided at the top.

[0079] The system preferably includes a test station that verifies whether the container's fill level corresponds to the target fill level. This test station is used, for example, during the initial setup or commissioning of the system at the start of a production process and serves purposes such as calibrating the sensor system and / or the at least one adjustment mechanism and / or checking machine settings. This ensures that the actual production process runs as smoothly as possible by reducing the reject rate of insufficiently filled containers. The check can be performed on a sample basis or, for example, on a predetermined number of containers.

[0080] For example, the filled container can be transported to the inspection station via a transport system (such as a robotic transport system) and, after inspection, transported back to the filling station or a closing station. Alternatively, the container can be removed from a common carrier and placed back into it.

[0081] The system preferably includes a closing station downstream of the filling station in one processing direction, wherein, after the containers have been filled by means of the closing station, a plug element can be inserted into the respective container via the insertion opening, preferably in a defined target position. Since the fill level can be precisely determined by the device according to the invention, it is also possible to position the plug element as desired at the defined target position.

[0082] The plug element is inserted into the container, for example, using a vacuum plugging process, up to the fill level with no air bubbles or only a very small air bubble. In this way, the position of the plug element is influenced by the fill level, which is why its precise determination is important.

[0083] A target position of the plug element can be determined, in particular with regard to the reference position mentioned at the beginning.

[0084] If the containers are arranged in a common carrier, they are, for example, sealed while they are in the carrier.

[0085] It may be possible to have the container checked at the aforementioned testing station to verify that the position of the stopper element corresponds to the target position. For example, during the initial setup or commissioning of the system at the start of a production process, after the filling station check and the container sealing, the position of the stopper element is checked to ensure the most error-free process possible. This check can be performed on a sample basis or, for example, on a predetermined number of containers.

[0086] The aforementioned transport device can be used, for example, to transport the sealed container. The container can be removed from a common carrier and placed back into it.

[0087] The system can advantageously include a control station downstream of the closing station in one processing direction. At the control station, which is used particularly during the production process after learning or commissioning, the fill level and / or the height of the stopper element can be checked, for example.

[0088] The at least one processing station can include a further filling station located upstream of the filling station in one processing direction of the system. At this further filling station, the containers are pre-filled with the product to a first fill level and then filled to the target fill level at the filling station using the filling needle device. This increases the cycle time of the system. At the first filling station, the containers can preferably be pre-filled with a high flow rate. For example, filling needles with a larger diameter than those used at the filling needle device can be employed here. In practical applications, for example, filling needles with an inner diameter of approximately 2 to 3 mm can be used (e.g., for fill quantities of approximately 2 to 5 ml), while the filling needle of the filling needle device has an inner diameter of, for example, 0.5 mm to 1 mm.The smaller filling needle of the filling device, compared to the first filling needle, is advantageous because it allows only a small flow rate, thus enabling precise termination of the filling process. The smaller diameter also provides space for the electrode that is inserted into the container. During pre-filling, the container can be filled relatively quickly, for example, from approximately 70% to approximately 95%. Using the device according to the invention, the remaining product is filled to the target fill level.

[0089] It is understood that the dimensioning of the filling needles and any supply lines may differ from the examples mentioned above, depending on the dosage quantity and the product, and can be designed accordingly by a specialist for the respective product and / or performance range.

[0090] The dosing unit preferably determines the quantity of product to be dispensed to fill the containers from the initial fill level to the target fill level. Depending on this determination, a dosing unit at the next filling station can be controlled to pre-fill with a larger or smaller quantity of product to achieve a higher or lower initial fill level. This allows for optimization of the system's operation. For example, there can be feedback between the two filling stations, with the respective fill levels being automatically adjusted. If the initial fill level is too low, the cycle time can be increased by dispensing more product during pre-filling. Conversely, if the initial fill level is so high that the accuracy in determining the target fill level might be compromised, less product can be pre-filled.

[0091] The system can include a gas supply unit coupled to the control unit, which is in flow communication with the connection element on the holding body via a supply line, wherein the gas supply unit can be selectively activated to supply the filling needle unit with gas. This allows any drops of product at the filling needle unit to be blown off.

[0092] The system can include a transport device coupled to the control unit, by means of which the filling needle device and the container can be selectively moved relative to each other, whereby the gas supply device can be activated when the filling needle device is in a cleaning position relative to the container. For example, the filling needle device can be moved laterally relative to the container and vented in a cleaning position there. Alternatively, it can be provided that the container moves relative to the stationary filling needle device and the latter consequently assumes a cleaning position in order to vent liquid.

[0093] It is understood that the gas supply device may, for example, include a valve element to selectively release or block the supply line.

[0094] Automated calibration of the adjustment device can be provided to ensure the most suitable target position of the filling needle relative to the container, especially at the beginning of the filling process. For example, the measurement signal can be evaluated to determine when the target fill level is reached and the position of the filling needle relative to the container. If necessary, the adjustment device can be dynamically adjusted during operation to change the relative position for setting the fill level.

[0095] A method according to the invention for filling a container with a product, in particular a pharmaceutical container with a pharmaceutical product, using a device or system of the type described above, comprises: - Inserting the filling needle device through an insertion opening into the container; - as part of the filling needle device or separately from it, insertion of at least one electrode into the container; - Activating the dosing device after or during insertion; - Capturing or determining a measurement signal that is indicative of the fill level of the product in the container; and - Providing a stop signal directly or indirectly to the dosing device to end the filling process when a target fill level is reached.

[0096] The advantages and effects already mentioned in connection with the explanation of the device and the system according to the invention can be achieved when carrying out the method. Advantageous embodiments of the method result from advantageous embodiments of the device and advantageous embodiments of the system. Reference is made to the above explanations.

[0097] The method is particularly suitable for filling containers in a common carrier, especially crimped cartridges, wherein the insertion opening is the opening through which a plug element is inserted at a later time.

[0098] However, as already mentioned, the present invention is not limited to such an application and to such a type of installation.

[0099] The following description of preferred embodiments of the invention, in conjunction with the drawing, serves to explain the invention in more detail. The drawing shows: Fig. 1: a schematic representation of the system according to the invention in a preferred embodiment; Fig. 2: a schematic view of part of the plant, showing a carrier with several containers and a filling needle device for filling the containers; Fig. 3: a schematic representation of a filling needle device (partial view) and a container at the beginning of a filling process; Fig. 4: a representation accordingly Fig. 3 at the end of the filling process; Fig. 5: an enlarged view of detail A in Fig. 3 and an evaluation unit to explain a measurement principle in the device according to the invention; Fig. 6: the filling needle device (partial illustration) and the container as well as an evaluation unit to explain the measuring principle of the device according to the invention; Fig. 7: a perspective view of a filling needle device of the device according to the invention in a preferred embodiment, partially cut away; Fig. 8: the filling needle device from Fig. 7, partly as an exploded view; Fig. 9: a top view of the filling needle device Fig. 7; Fig. 10: a sectional view along line 10-10 in Fig. 9; Fig. 11: Several diagrams as a function of time to illustrate the measuring principle of the device according to the invention; Fig. 12: a representation accordingly Fig. 11, obtained during the bottling of a different type of product; Fig. 13: a representation accordingly Fig. 11, obtained using a variant of the measurement principle; Fig. 14: schematically a part of a variant of the filling needle device of the device according to the invention; Fig. 15: schematically a part of a variant of the filling needle device of the device according to the invention; and Fig. 16: schematically a part of a variant of the filling needle device of the device according to the invention.

[0100] Fig. Figure 1 shows a schematic representation of an advantageous embodiment of the system according to the invention, designated overall by reference numeral 100, for processing containers, in particular pharmaceutical containers, which are filled with a product, in particular pharmaceutical. The product is, in particular, liquid. The invention is explained below using the example of containers 102 in the form of cartridges 104, but is not limited to filling cartridges 104. Furthermore, for the purpose of illustrating the invention, it is assumed here by way of example that the cartridges 104 are received in a common carrier 106, configured as a nest 108 ( Fig. 2) Nest 108 is inserted into a Tub 109.

[0101] In its intended use, the carpules 104 in the present example are received in the nest 108 such that a first end 110, to which a crimp cap 112 is attached, is located at the bottom. A second end 114 opposite is located at the top. An insertion opening 116 is formed at the second end 114. The insertion opening 116 of the carpule 104 has a larger cross-section than a corresponding opening 118 at the first end 110.

[0102] In this example, the system 100 comprises a staging station 120 at or via which the nests 108 are provided. Downstream in one processing direction, the system 100 comprises a filling station 122 for partially filling the containers 102 with the product. In this case, the product is, in particular, a liquid. For this purpose, the filling station 122 comprises a metering device 124 and a filling needle device 126 with one or more filling needles.

[0103] Alternatively, the product can be non-liquid, for example, a powder.

[0104] The system 100 comprises a control unit 128, with which the operation of the system 100 can be controlled and / or regulated. The control unit 128 is coupled to the dosing unit 124 and to a transport unit for moving the filling needle unit 126 and the containers 102 relative to each other.

[0105] At filling station 122, the containers 102 are partially filled until the product in container 102 reaches an initial fill level of 130. For this purpose, the filling needles of the filling needle device 126 can have a comparatively large cross-section to provide a high volume flow rate for achieving a high cycle time of the system 100.

[0106] The system 100 further comprises another filling station 132. The filling station 132 is located downstream of the filling station 122 in the processing direction. It comprises the device 134 according to the invention in a preferred embodiment, which includes a filling needle device 136 and a sensor device 138. The sensor device 138 can, for example, be partially (e.g., in the form of the evaluation unit) a component of the control device 128 or be formed by it. In the present example, these devices 128 and 138 are in Fig. 1 shown separately. Conversely, the sensor device 138, for example its evaluation unit, can form the control device 128.

[0107] The filling station 132 also includes a dosing unit 140, which is coupled to the control unit 128. If the sensor unit 138 is separate from the control unit 128, these units 128 and 138 are coupled to each other.

[0108] Furthermore, the system 100 includes a gas supply device 142 for supplying a gas, for example compressed air and / or nitrogen.

[0109] At least one adjusting device 144, 145 is arranged at the filling station 132, in this case each designed as a lifting device 146 ( Fig. 2).

[0110] Downstream of the filling station 132 in one processing direction, the system 100 includes a closing station 148. After the containers 102 have been filled with the product at the filling station 132 up to a target fill level 166, they can be closed at the closing station 148 using plug elements 150. Fig. Figure 2 schematically shows such a plug element 150, which is inserted into the container 102 at the closing station 148 via the insertion opening 116.

[0111] To ensure that the stopper element 150 is in a precisely defined target position, it is important to make sure that the container 102 is filled to the specified target fill level 166. In its intended use, the stopper element 150 serves as a stop element for a product dispensing device.

[0112] This applies, for example, to dispensing devices in the form of injection pens, where the cartridges 104 contain insulin. Reliable positioning of the stopper element is necessary to ensure the function of the insulin pen and the amount of insulin dispensed. The target position of the stopper element 150 can be determined with respect to a reference position, for example, the end 110 of the cartridge 104.

[0113] The system 100 can have a control station 152 downstream of the closing station 148. At the control station 152, for example, optical sensors can be used to check the fill level and the position of the stopper element 150, and generally the proper condition of the containers 102. Defective containers 102 can preferably be sorted out.

[0114] Reference numeral 154 designates a handling device of plant 100, specifically designed to ensure the transport of the nests 108 within plant 100. It is understood that the handling device 154 can be controlled by the control unit 128 and may comprise several individual components for specific transport sections.

[0115] For example, from Fig. As shown in Figure 2, the filling needle assembly 136 can include a holding body 156. At least one filling needle 158 can be held on the holding body 156. In the present example, two filling needles 158 are shown, with which adjacent rows 160 of containers 102 in the nest 108 can be filled. It is conceivable that the filling needle assembly 136 includes enough filling needles 158 to be able to fill at least one row 160 simultaneously. The filling needle assembly 136 can therefore be configured with multiple needles.

[0116] The system includes a dosing device 140 assigned to each filling needle 158. This allows each container 102 to be filled individually.

[0117] The more detailed method of fixing the filling needle 158 to the holding body 156 is described in Fig. 2 not shown. A subsequent example based on the Fig. Figures 7 to 10 describe a preferred embodiment of the filling needle device 136, which shows its features in detail. This type of fixation is not strictly necessary for the purpose of explaining the invention.

[0118] The lifting device 146 is used to fill the containers 102. The lifting device 146 comprises a drive unit 162 and, assigned to each container 102 to be lifted, a lifting element 164, which may in particular be a plunger. When the respective container is to be filled, the drive unit 162 is activated, and the container 102 is lifted, as shown in Fig. Figure 2 is shown as an example for two (or two rows) of containers 102.

[0119] The filling needle device 136 can be lowered via the further adjustment device 145.

[0120] Due to the relative movement of the container 102 and the filling needle device 136, the filling needle device 136 engages, at least partially, in the container 102 via the insertion opening 116, as explained below. The filling needle 158 and the electrodes 178, 180 are arranged in the container 102.

[0121] For electrodes that are not held on the filling needle device 136 or formed by the filling needle, a separate adjustment device can be used, for example.

[0122] The filling process can begin when the relative position no longer changes and, accordingly, the filling needle device 136 has a defined position in the container 102. Alternatively, it can be provided that the filling process begins during insertion.

[0123] For the intended use of the cartridges 104, the target fill level 166 is set relative to a reference position. In this case, the lower end 110 of the cartridge 104 is used as the reference position, where the crimp cap 112 is located and over which the cartridge 104 is supported on the lifting element 164.

[0124] The fill level can be measured when filling container 102.

[0125] When the product level in container 102 reaches the desired target level 166, the filling process is completed. Container 102 is then lowered again via the lifting device 146. Further containers 102 can then be filled. Once all containers 102 in the nest 108 are filled, the nest 108 is transported to the closing station 148 to insert the plug elements 150. Alternatively, the closing station 148 can insert the plug elements 150 while further containers 102 in the nest 108 are still being filled.

[0126] The plug elements 150 are inserted into the containers 102 using vacuum plug insertion, up to the target fill level 166 without air bubbles or with only a very small air bubble. In this way, the position of the plug element 150 is influenced by the fill level.

[0127] The dosing device 140 preferably determines the quantity of product to be dispensed to fill the container 102 from the initial fill level 130 to the target fill level 166. Depending on this, the dosing device 124 of the filling station 122 can be controlled for pre-filling, dispensing a larger or smaller quantity of product for a higher or lower initial fill level, respectively.

[0128] For example, if a relatively large quantity of product needs to be filled via the dosing device 140, the fill level at the filling station 122 can be increased to raise the initial fill level 130. This is advantageous, for instance, because filling via the filling needle device 136, whose filling needle has a smaller cross-section than the filling needle of the filling needle device 126, is slower than at the filling station 122.

[0129] If, on the other hand, the quantity of product to be filled at filling station 132 is relatively small and / or the target fill level 166 can only be measured imprecisely, the dosing unit 124 can be controlled to implement a lower fill level during pre-filling. This can be the case, for example, if the initial fill level 130 is close to or very close to the target fill level 166.

[0130] It is understood that the above-described adjustment is possible during the ongoing operation of plant 100.

[0131] The measuring principle of the device 134 according to the invention is described below, in particular with reference to the Fig. 2 to 6 explained.

[0132] The filling needle device 126 has at least one filling needle 158. In this case, the filling needle 158 comprises a base body 168, which is configured as a bushing 170. The filling needle 158 further comprises a tube 172, which is fluidically connected to the base body 168. A connection element 174 for connecting a supply line for the product, which is conveyed by the metering device 140, is arranged on the base body 168. The metering device 140 is, for example, a peristaltic pump.

[0133] Furthermore, the filling needle device 136 comprises a sleeve 176. The sleeve surrounds the tube 172, with a gap formed between the tube 172 and the sleeve 176. The tube 172 and the sleeve 176 are aligned coaxially with each other.

[0134] The sensor device 138 is an electrical sensor device and is designed here for capacitive measurement. This is evident from the Fig. 5 and Fig. 6. The sensor device 138 comprises a first electrode 178 and a second electrode 180. In this case, the tube 172, and thus the filling needle 158, forms the first electrode 178. The sleeve 176 forms the second electrode 180.

[0135] The sleeve 176 is held in a defined and, in particular, unchanging relationship relative to the filling needle 158 on the filling needle device. This ensures that the spatial relationship between the electrodes 178 and 180 does not change before, during, or after the filling process. This guarantees consistently reliable measurement conditions.

[0136] An electrical insulating element 182 is arranged between the electrodes 178, 180. The insulating element 182 is designed as a sleeve 184, the inner circumferential surface of which rests against the outside of the tube 172 ( Fig. 3 and Fig. 4) The sleeve 184 electrically insulates the electrodes 178, 180 from each other.

[0137] The sleeve 184 can form a contact flange 186, which in the present example abuts a protective element 190, also designed as a sleeve 188. The protective element 190 surrounds the sleeve 176 section by section in the area that cannot be inserted into the container 102. For example, the sleeve 188 can form a contact flange for abutting the retaining body 156.

[0138] The filling needle 158 can, for example, be held on the holding body 156 via the base body 168.

[0139] During the Fig. In the embodiment of the filling needle device 136 shown in Figures 2 to 7, the tube 172 projects beyond the sleeve 176 with respect to an insertion direction 192 into the container 102. As the liquid level rises, the tube 172 comes into contact with the liquid before the sleeve 176 also makes contact with the liquid.

[0140] Such a design proves, for example, to be suitable for measuring fill levels, especially for liquids with low conductivity, such as water or water-containing substances.

[0141] Electrodes 178 and 180 are connected via electrical leads 194 to a voltage source 196 of the evaluation unit 198 of the sensor device 138. An ammeter 200 can, for example, be connected in one of the leads 194. An electrical potential difference between electrodes 178 and 180 can be set or maintained via the voltage source 196. For this purpose, a current can flow through the ammeter 200 when the electric field changes. Provided the sensor device 138 is appropriately calibrated, this current can be indicative of the liquid level in the container 102. Accordingly, a measurement signal indicative of the liquid level can be detected or determined by the evaluation unit. An output signal, in particular a stop signal for the dosing device 140, can be provided to the control unit 128 (arrow 202).Based on this, the control unit 128 can deactivate the dosing unit 140 when the target fill level is reached.

[0142] Fig. Figure 5 schematically shows how, starting from the initial fill level 130, the liquid is filled into the container 102. The quantity of product filled via the filling station 132 is shown in Fig. 5 schematically marked by densely dotted areas 204.

[0143] In the present example, the device 134 is calibrated such that the fill level corresponds to the target fill level 166 when the tube 172 of the filling needle 158 just makes contact with the liquid. Reference numeral 206 schematically shows the electric field between the electrodes 178 and 180. This field changes significantly, as can be seen in practice, when the target fill level 166 is reached.

[0144] Fig. Figure 6 schematically shows the filling needle device 136 in a partial view with the container 102, as well as the sensor device 138 with additional details. The electrical lines 194 are provided, for example, by a shielded coaxial cable 208. It may be provided that the sleeve 176 is at ground potential (GND) and the tube 172 at a correspondingly higher potential.

[0145] The evaluation unit 198 can include an amplifier unit 210, comprising, for example, an operational amplifier, connected downstream of the current measuring device 200.

[0146] Adjustment elements 212 may be provided to adjust a frequency in the case of an alternating voltage, an amplitude of the voltage, a gain factor and / or an offset.

[0147] Fig. Figure 11 shows, as an example, several curves as a function of time (abscissa) during the operation of plant 100 (ordinates). The process shown here is for filling a container 102.

[0148] A dashed line 214 shows the relative position of the filling needle 158 and the container 102 as a function of time (with the ordinate reversed). At the initial time t0, the filling needle assembly 136 enters the container 102, so that the tube 172 of the filling needle 158, together with the sleeve 176 forming the second electrode 180, is partially positioned in the container 102. Once a target position is reached at a second time t1, the filling process is started by activating the metering device 140. A dashed line 216 symbolically represents the operating cycle of the peristaltic pump of the metering device 140.

[0149] A solid line 218 represents the measurement signal of the evaluation unit 198. It can be measured during filling. It can be seen that the measurement signal increases as the filling process begins. At time t2, the measurement signal suddenly rises sharply. The sensor device 138 is set and the relative position of the filling needle 108 and the container 102 is calibrated such that this sharp increase in the measurement signal 218 indicates that the target fill level 166 has been reached, for example, when the pipe 172 touches the liquid.

[0150] A horizontal dashed line 220 represents a threshold value 222 for the measurement signal 218. If the threshold value 222 is exceeded by the measurement signal 218, it is assumed that the target fill level 166 has been reached.

[0151] A dotted line 224 schematically represents a stop signal to stop the dosing device 140.

[0152] A dashed line 226 symbolizes the machine cycle of plant 100.

[0153] It can be seen that after the dosing device 140 is switched off, the container 102 is moved again relative to the filling needle 158, in particular lowered. This can be seen from line 214. It can also be seen that the measurement signal 218 drops sharply during this movement.

[0154] As a result, the exemplary measurement curves illustrate according to Fig. 11, that the target fill level of 166 can be reliably determined.

[0155] While in Fig. 11 the verification is carried out using a rising edge of the measurement signal 218, shows Fig. 12. A representation of measurement curves recorded during the filling of a different type of product. A total of four cycles are shown as a function of time; that is, the measurement curves extend over the time required to fill four containers. 102.

[0156] It is evident that the measurement signal 218 rises sharply at the beginning of the filling process and then continues to increase. Subsequently, a falling edge can be observed, during which the measurement signal 218 drops sharply at time t2. This is considered indicative of the target fill level 166 being reached. The dosing unit 140 is deactivated at this time, as can be seen from the dotted line 224.

[0157] In the examples of Fig. 11 and Fig. 12 the sensor device 138 is operated capacitively.

[0158] An exemplary application in a conductive operation of the sensor device 138 is shown Fig. 13. Based on measurement curves. It can be seen that some time after the start of the filling process, the measurement signal 218 suddenly rises sharply. This is considered indicative of the target fill level being reached. When this sharply rising edge occurs, the dosing device 140 is deactivated, as can be seen from the dotted line 224.

[0159] The exemplary illustrations of Fig. 12 and Fig. Figure 13 shows that the device 134 according to the invention reliably detects when the target fill level 166 is reached. If this is the case, the filling process is terminated.

[0160] In particular, it is shown that the required accuracy can be achieved to allow the plug element 150 to be inserted into the container 102 with the required accuracy.

[0161] The embodiment of the filling needle device 136, which is described in the Fig. Figures 2 to 6, in which the tube 172 extends beyond the sleeve 176 in the insertion direction 192, proves to be suitable, for example, for measurements on liquids with relatively low conductivity.

[0162] A test station 227 can be used during the initial setup or commissioning of the system 100 ( Fig. 1) The test station ensures, prior to the actual production process, that the target fill level 166 is maintained and the stopper element 150 is in the correct target position. This ensures that the actual production process runs as smoothly as possible by reducing the reject rate of insufficiently filled containers 102. The check can be carried out on a sample basis or, for example, on a predetermined number of containers 102. In the event of any deviations from the target values, changes to the settings of the system 100 can be made automatically and / or manually by an operator. This includes, for example, calibrating the sensor device 138 and / or the adjustment devices 144, 145.

[0163] Using a transport device (for example, marked with reference numeral 268), the filled container 102 can be moved to the testing station 227 and, after inspection, placed back into the nest 108. The plug element 150 is then inserted, and the container is transported to the testing station 227 again for inspection.

[0164] The following describes an embodiment of the filling needle device 136, which is described in the Fig. Figures 7 to 10 illustrate this embodiment. This embodiment is particularly advantageous for measurements on liquids with higher conductivity, such as insulin. However, practical experience has shown that this embodiment is also suitable for liquids with lower conductivity and is therefore versatile.

[0165] The filling needle device 136 according to the Fig. 7 to 10 can be used instead of the filling needle device 136 according to the Fig. 2 to 6 are used in the device 134 according to the invention. Identical reference numerals are used for identical or equivalent features and components.

[0166] The filling needle assembly 136 comprises the holding body 156. A projection 228 is arranged on the holding body 156, on which a holding area 232 for a filling needle 158, as well as a sleeve 176, an insulating element 182, and a sleeve 188 are arranged. These components 158, 176, 182, and 188 are referred to, for example, as the filling unit 230. Accordingly, a holding area 232 is provided on the projection 228 for the filling unit 230.

[0167] The filling needle device 136 has a further holding area 232. A recess 236 is formed laterally next to the projection 228, on which the second holding area 232 is arranged. A further filling unit 230 is held on the holding area 232.

[0168] Accordingly, the embodiment is also according to the Fig. 7 to 10 two-digit numbers. However, the two filling units 230 are arranged relative to each other with an offset or staggered arrangement, as can be seen in particular from the top view of Fig. 9 can be seen. This means that when the filling needle device 136 is used, one container 102 of a row 160 and one adjacent row 160 of the nest 108 are filled.

[0169] The filling units 230 and the respective design of the holding areas 232 are identical, so that only one design will be discussed below.

[0170] A first receptacle 238 is arranged at the holding area 232. The receptacle is essentially semi-cylindrical in shape and has a rim 240. The filling needle 158 is held in the receptacle 238, with the base body 168 engaging positively in the receptacle 238. The base body 168 has a contact flange 242 that rests against the rim 240.

[0171] Below the recording 238, a second recording 244 is formed. The second recording 244 is also essentially semi-cylindrical in its contour and includes a rim 246.

[0172] The protective element 190 is positively engaged in the receptacle 244 and in turn surrounds the sleeve 184 of the insulating element 182. The sleeve 184 rests against the protective element 190 via the mounting flange 186 and against the retaining body 156 via the latter. The base body 168 rests against the sleeve 184.

[0173] The insulating element 182 extends through the sleeve 188. On an inner circumferential surface, the insulating element 182 rests against the tube 172. Radially on the outer side, however, a gap 250 is formed between the insulating element 182 and the sleeve 176.

[0174] Spacers 252 are arranged radially on the outside of the insulating element 182, which contact the sleeve 176 on the inside and thus ensure a reliable fit of the insulating element 182 in the sleeve 176.

[0175] With respect to its longitudinal extent, the insulating element 182 can extend over almost the entire length of the pipe 172 and the sleeve 176, as shown in the Fig. 7 and Fig. Figure 10 is shown. For example, the extent is at least approximately half the length of the sleeve 176 and the tube 172.

[0176] The sleeve 176 projects beyond the tube 172 at its lower end, relative to the insertion direction 192. At its end, the sleeve 176 has at least one point 254. In this case, there are two opposing points 254. Between each point 254, a concave recess 256 is formed on the sleeve 176, which in this example is U-shaped.

[0177] A connection element 258 is arranged on the holding body 156. A supply line 260 can be connected to the connection element 258 in order to bring the filling needle device 136 into flow communication with the gas supply device 142.

[0178] In the holding body 156 a branching flow channel 262 is formed, so that incoming gas can flow through the holding body 156 to a respective filling unit 230 ( Fig. 10).

[0179] For this purpose, a through-opening 264 is formed in the protective element 190, which aligns with a corresponding through-opening 266 in the sleeve 176. Gas flows through the through-openings 264 and 266 into the space 250 between the sleeve 176 and the insulating element 182. The gas can then flow further to the lower end of the filling unit 230.

[0180] If the filling unit 230 becomes wetted with or immersed in the liquid during filling, liquid may adhere to the sleeve 176 or the tube 172. The gas supply device 142 can be activated to supply gas, in particular compressed air or nitrogen, in order to blow off any adhering liquid through the supply line 260, the flow channel 262 and the space 250.

[0181] It may be provided that the liquid is blown off while the filling unit 230 is still located in the container 102. Alternatively, it may be provided that the filling needle device 136 and the containers 102 are moved relative to each other via a transport device 268 until the filling needle device 136 is in a cleaning position, particularly outside of a region of the containers 102. Liquid can be blown off at a distance from the containers 102.

[0182] During the filling process, a protective gas such as nitrogen can preferably be introduced into container 102 to protect the product from oxidation. The protective gas can, for example, be supplied through the space 250.

[0183] The possibility of multiple digits was, for example, mentioned in connection with the Fig. 2 already received. In the filling needle device 136, each filling needle 158 is assigned a pair of electrodes 178, 180. The fill levels of the containers 102 can thus be individually determined by means of the evaluation unit 198. Furthermore, since each filling needle 158 is assigned a dosing device 140, the filling of each container 102 can be individually controlled and checked. This is advantageous, for example, because mechanical tolerances can occur in the function and condition, for example of the adjusting devices 144, 145. Any component tolerances can also be compensated for by the individual control.

[0184] Alternatively or additionally, it may be provided that the lifting elements 164 can be individually controlled for each container 102 in order to compensate for mechanical deviations.

[0185] Fig. Figure 14 shows a different variant of a filling needle device 136. Here, electrodes 178, 180 are provided, which are formed separately from the tube 172 and are, for example, needle-shaped. The electrodes 178, 180 project beyond the tube 172 of the filling needle 158.

[0186] The electrodes 178, 180 are fixed to the sleeve 176 or to the tube 172 by means of two retaining elements 270 in the present example, designed as retaining rings.

[0187] Fig. Figure 15 shows a variant of the filling needle device 136 in which the electrodes 178, 180 are printed onto a flexible retaining element 272 by means of electrical conductors. The retaining element 272 can be adapted to the contour of the filling needle 158 and connected to it, for example by gluing. The electrodes 178, 180 can protrude downwards, for example beyond the tube 172. The retaining element 272 can be fixed to the sleeve 176 or to the tube 172.

[0188] Alternatively, the electrodes 178, 180 can be printed using 3D printing, for example onto the sleeve 176 or the tube 172. The retaining element 272 can then be omitted.

[0189] Fig. Figure 16 shows another sleeve 274, which could, for example, be used instead of the sleeve 176. Unlike the variants described so far, the sleeve 274 has only one point 254. Its lower end is chamfered at an angle relative to an axis of the sleeve 274. Liquid droplets are also less likely to adhere to the sleeve 274 than in the variant according to the Fig. 7 to 10 was described. Reference symbol list 100 plant 102 containers 104 carpules 106 carriers 108 Nest 109 Tub 110 first end 112 crimp cap 114 second end 116 Insertion opening 118 Opening 120 deployment station 122, 132 Filling station 124, 140 Dosing device 126, 136 Filling needle device 128 Control unit 130 first fill level 134 Device 138 Sensor device 142 Gas supply unit 144, 145 Adjustment device 146 Lifting device 148 Locking Station 150 plug element 152 Control Station 154 Handling device 156 retaining bodies 158 Filling needle 160 row 162 Drive unit 164 lifting element 166 Target fill level 168 Basic bodies 170 socket 172 pipe 174, 258 Connection element 176, 184, 188, 274 Sleeve 178 electrode 180 electrode 182 Insulation element 186, 242, 248 Mounting flange 190 protective element 192 Insertion direction 194 electrical lines 196 Voltage source 198 evaluation units 200 current meter 202 Arrow 204 area 206 electric field 208 coaxial cables 210 amplifier unit 212 Adjustment element 214 dashed line (relative position of filling needle device and container) 216 dashed line (dispensing device) 218 solid line (measurement signal) 220 dashed line 222 Threshold 224 dotted line (switching signal) 226 dashed line (machine) 228 lead 230 filling unit 232 stopping area 236, 256 Exclusion 238, 244 recording 240, 246 Rand 250 space 252 Spacer 254 peak 260 Supply line 262 Flow channel 264 Passage opening 266 Passage opening 268 Transport equipment 270 retaining element 272 Holding element QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2012 207 587 A1

[0009] WO 2023 / 174645 A1

[0010] CN 102 944 286 A

[0012]

Claims

[1] Device (134) for filling containers (102) with a product, in particular a liquid, in a filling process, in particular a pharmaceutical container (102) with a pharmaceutical product, comprising a filling needle device (136) which includes or forms a filling needle (158) for dispensing the product and which can be inserted into the container (102) via an insertion opening (116), and a sensor device (138) by means of which a fill level (130, 166) of the product in the container (102) can be determined, characterized by, that the sensor device (138) is designed as an electrical, in particular as a capacitive and / or as a conductive, sensor device (138) and comprises a first electrode (178) and a second electrode (180) as well as an evaluation unit (198) coupled to the electrodes (178, 180), wherein at least one of the electrodes (178, 180) can be inserted into the container (102), wherein a measurement signal (218) can be detected or determined by the evaluation unit (198) when the container (102) is filled, which is indicative of the fill level of the product in the container (102), and wherein a stop signal can be provided directly or indirectly to a dosing device (140) to terminate the filling process. [2] Device (134) according to claim 1, characterized by, that at least one electrode (178, 180) is held or arranged on the filling needle device (136) in a defined, in particular unchanging, spatial relationship to the filling needle (158) and can be inserted into the container (102) with the filling needle (158), and / or that the filling needle (158) forms an electrode (178, 180). [3] Device (134) according to claim 1 or 2, characterized by , that the first electrode (178) and the second electrode (180) are held or arranged on the filling needle device (136) in a defined, in particular unchanging, spatial relationship to the filling needle (158). [4] Device (134) according to claim 1 or 2, characterized by , that an electrode (178, 180) is formed by a component of the container (102) to be filled, in particular by a closure element that is arranged on a side of the container (102) facing away from the insertion opening (116), or that an electrode is formed separately from the container (102). [5] Device (134) according to any one of claims 1 to 3, characterized by , that the first electrode (178) is or comprises a tube (172), in particular the filling needle (158) or as a component of the filling needle (158), and that the second electrode (180) is or comprises a sleeve (176) that surrounds the tube (172) and is preferably aligned coaxially with it. [6] Device (134) according to claim 5, characterized by , that the filling needle (158) or the tube (172) extends beyond the sleeve (176) or that the sleeve (176) extends beyond the filling needle (158) or the tube (172). [7] Device (134) according to claim 5 or 6, characterized by that the sleeve (176) comprises or forms at least one point (254) at its end, in particular two opposing points (254), between which preferably concave recesses (236, 256) are formed on the sleeve (176). [8] Device (134) according to any one of claims 5 to 7, characterized by, that the filling needle device (136) comprises an electrical insulating element (182) which is arranged between the tube (172) and the sleeve (176) and extends at least sectionally along a portion of the tube (172) and the sleeve (176). [9] Device (134) according to claim 8, characterized by , that the insulating element (182) comprises a mounting flange (186, 242, 248) and rests on a retaining body (156) of the filling needle device (136) via this flange and forms a mounting element on which the filling needle (158) rests with a base body (168) which is flow-connected to the pipe (172). [10] Device (134) according to claim 8 or 9, characterized by, that the insulating element (182) contacts the tube (172) on an inner circumferential surface and / or the sleeve (176) on an outer circumferential surface and / or that spacers (252) are arranged or formed on the insulating element (182) via which at least one gap (250) is formed between the insulating element (182) and the sleeve (176) and / or between the insulating element (182) and the tube (172). [11] Device (134) according to claim 9 or 10, characterized by , that the filling needle device (136) comprises a retaining body (156) on which the filling needle (158) and the sleeve (176) are held, and a connecting element (258) arranged on the retaining body (156) for a supply line (260), wherein the connecting element (258) is in flow communication with the at least one intermediate space (250). [12] Device (134) according to claim 11, characterized by, that to provide the flow connection in the holding body (156) a flow channel (262) is formed which opens directly or indirectly into the at least one space (250) for supplying the at least one space (250) with gas. [13] Device (134) according to any one of the preceding claims, characterized by , that the filling needle device (136) comprises two or more filling needles (158) and preferably a retaining body (156) to which the filling needles (158) are fixed, wherein two or more containers (102) can be filled via the filling needles (158). [14] Device (134) according to claim 13, characterized by, that the sensor device (138) comprises two or more first electrodes (178) and second electrodes (180), wherein a first electrode (178) and a second electrode (180) are assigned to each filling needle (158), wherein a measurement signal (218) can be detected or determined by the evaluation unit (198) when filling the respective container (102), which is indicative of the fill level of the product in the container (102), and wherein a stop signal can be provided directly or indirectly to a dosing device (140) to terminate the filling process. [15] Device (134) according to any one of the preceding claims, characterized by, that the retaining body (156) comprises or forms a respective retaining area (232) on which a respective filling needle (158) is held, wherein a retaining area (232) is formed on a projection (228) of a housing of the retaining body (156), wherein the filling needle (158) is arranged on the side facing away from the housing on the projection (228), and wherein a recess (236) is formed laterally next to the projection (228) in which the other filling needle (158) is arranged. [16] Device (134) according to any one of the preceding claims, characterized by , that the filling needle device (136) comprises two electrodes (178, 180) which are formed separately from the filling needle (158) and are fixed to the filling needle (158) or to a sleeve (176) surrounding the filling needle (158) via at least one retaining element (270). [17] Device (134) according to any one of the preceding claims, characterized by, that the electrodes (178, 180) are printed as electrical conductors onto a preferably flexible holding element (272) or onto the filling needle device (136). [18] Device (134) according to any one of the preceding claims, characterized by a continuous detection or determination of a measurement signal (218) or by detection or determination of the measurement signal (218) at time intervals by the sensor device (138). [19] Device (134) according to any one of the preceding claims, characterized by, that the evaluation unit (198) provides an electrical voltage between the first electrode (178) and the second electrode (180) for a capacitive or conductive measurement and that as a result of a changing distance between the at least one electrode (178, 180) in the container (102) and the further electrode (178, 180) a change in voltage and / or a change in current flow between the electrodes (178, 180) can be detected. [20] Plant (100) for processing containers (102), in particular pharmaceutical containers (102), comprising at least one processing station for processing the containers (102), comprising a filling station (122, 132), wherein the filling station (122, 132) comprises a metering device (140) and a device (134) according to one of the preceding claims, a control unit (128) coupled with the dosing device (140) and the sensor device (138), and at least one adjusting device (144, 145) for providing a relative movement between at least one container (102) and the filling needle device (136) and / or between at least one container (102) and at least one electrode (178, 180), wherein in the operation of the system (100) the filling needle (158) and the at least one electrode (178, 180) are inserted into the container (102) via the insertion opening (116), a filling process is started in which the dosing device (140) is activated to fill the container (102) with the product, and wherein the dosing device (140) is deactivated to end the filling process when the fill level of the product in the container (102) reaches a predetermined target fill level (166). [21] Plant (100) according to claim 20, characterized by, that the at least one adjusting device (144, 145) is or comprises a lifting device (146) which includes a lifting element (164) by means of which the container (102) can be lifted in the direction of the filling needle device (136), and / or that the at least one adjusting device (144, 145) is or comprises a lifting device (146) by means of which the filling needle device (136) can be lowered in the direction of the container (102). [22] Plant (100) according to claim 21, characterized by , that the system (100) includes a handling device (154) for handling, in particular for transporting, a carrier (106) for a plurality of containers (102) and that at least one container (102) can be lifted at least partially from the carrier (106) in the direction of the filling needle device (136) via the lifting device (154). [23] Plant (100) according to one of claims 20 to 22, characterized by, that the containers (102) are pre-crimped carpules (104), wherein a pre-crimped end (110) of the carpule (104) is arranged on the underside of the carrier (106) and the insertion opening (116) is provided for the insertion of a plug element (150). [24] Plant (100) according to any one of claims 20 to 23, characterized by , that the system (100) includes a test station (227) with which the container (102) can be checked to see whether the fill level corresponds to the target fill level (166). [25] Plant (100) according to any one of claims 20 to 24, characterized by , that the system (100) comprises a closing station (148) downstream of the filling station (132) in a processing direction and that after the containers (102) have been filled by means of the closing station (148) a plug element (150) can be inserted into the respective container (102) via the insertion opening (116) preferably in a defined target position. [26] Plant (100) according to claim 25 in conjunction with claim 24, characterized by , that the container (102) can be checked with the test station (227) to ensure that the position of the plug element (150) corresponds to the target position. [27] Plant (100) according to claim 25 or 26, characterized by , that the plant (100) includes a control station (152) downstream of the closing station (148) in a processing direction. [28] Plant (100) according to any one of claims 20 to 27, characterized by , that at least one processing station comprises a further filling station (122) which is located upstream of the filling station (132) in a processing direction of the plant (100), wherein the containers (102) are pre-filled with the product at the further filling station (122) up to a first fill level (130) and are filled at the filling station (132) with the filling needle device (136) up to the target fill level (166). [29] Plant (100) according to claim 28, characterized by, that by means of the dosing device (140) it can be determined which quantity of the product is filled in order to fill the containers (102) from the first fill level (130) to the target fill level (166), and that depending on the determination a dosing device (124) of the further filling station (122) can be controlled to pre-fill a larger or smaller quantity of product to achieve a higher first fill level (130) or lower first fill level (130). [30] Plant (100) according to any one of claims 20 to 29, characterized by , that the system (100) comprises a gas supply device (142) coupled to the control device (128), which is in flow connection with the connection element (258) via a supply line (260), wherein the gas supply device (142) can be selectively activated to supply gas to the filling needle device (136). [31] Plant (100) according to claim 30, characterized by, that the system (100) comprises a transport device (268) coupled to the control device (128), by means of which the filling needle device (136) and the container (102) can be moved selectively relative to each other, and that the gas supply device (142) can be activated when the filling needle device (136) is in a cleaning position relative to the container (102). [32] Method for filling a container (102) with a product, in particular a pharmaceutical container (102) with a pharmaceutical product, with a device (134) according to one of claims 1 to 18 or a system according to one of claims 19 to 27, comprising: - Inserting the filling needle device (136) through an insertion opening (116) into the container (102); - as part of the filling needle device (136) or separately from it, insertion of at least one electrode (178, 180) into the container (102); - Activating the dosing device (140); - Detecting or determining a measurement signal (218) that is indicative of the fill level of the product in the container (102); and - Providing a stop signal directly or indirectly to the dosing device (140) to terminate the filling process when a target fill level (166) is reached.

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