Apparatus and method for filling containers and system for processing containers

Abstract

The present invention relates to an apparatus (134) for filling containers (102) with a product, in particular a liquid product, in a filling process, in particular for filling a pharmaceutical container (102) with a pharmaceutical product, the apparatus 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 capacitive and / or conductive, sensor device (138) and comprises a first electrode (178) and a second electrode (180) and an evaluation unit (198) coupled to the electrodes (178, 180); at least one of the electrodes (178, 180) can be inserted into the container (102); as the container (102) is being filled, the evaluation unit (198) can detect or determine a measurement signal (218) indicative of the fill level of the product in the container (102); and a stop signal can be provided to a metering device (140) in order to end the filling process. The invention also relates to a system for processing containers and to a method for filling containers.

Description

[0001] Device and method for filling containers and system for processing containers

[0002] The present invention relates to a device for filling containers with a particularly liquid product in a filling process, in particular a pharmaceutical container with a pharmaceutical product, comprising a filling needle device which comprises 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.

[0003] In this case, a “pharmaceutical product” can also be understood as a “medical product”.

[0004] Furthermore, the present invention relates to a method for filling a container with a product using a device of the type described above.

[0005] Furthermore, the present invention relates to a plant for processing containers, in particular pharmaceutical containers, with at least one processing station for processing the containers, which comprises a filling station having a device of the type described above.

[0006] When processing containers in such a system, it is desirable to be able to carry out the filling process in a standardized and as precise a manner as possible with regard to the use of the containers and the reliable functioning of a dispensing device in which the containers are used. For example, it is known that the quantity of product filled is determined based on its mass. For this purpose, the mass can be determined based on the difference between a gross weighing of the filled container and a tare weighing of the empty container. For other applications, however, it can be advantageous if the fill level of the product in the container is determined and, in particular, determined as precisely as possible. It is conceivable that a check of the fill level goes hand in hand with a check of the mass. However, this is not absolutely necessary.

[0007] Different fill levels for the same product mass can arise, for example, as a result of tolerances in the containers and / or the closure elements used. The present invention relates to a device and a method as well as a system in which the fill level of the product in a container can be determined as precisely as possible. Monitoring the fill level proves to be advantageous, for example, for applications in which containers are used in dispensing devices. These dispensing devices can be insulin pens, for example, where reliable function must be ensured from a mechanical point of view and the dispensing of the correct dose of product must be guaranteed. These dispensing devices particularly use carpules which have a crimp cap as a closure element on a first side and a plug element as a closure element on a second side.The stopper element serves as a stop element to define a correct target position in the insulin pen. For this reason, it is desirable that the stopper element be positioned at a defined target position with the greatest possible accuracy during container processing.

[0008] In the state of the art, there are, on the one hand, conventional solutions in which the carpules with a pre-inserted stopper element are filled through the opening to which the crimp cap is later attached. In practice, filling carpules through the narrow opening opposite the stopper element has proven to be reliable. However, checking the fill level is complex. Furthermore, due to equipment limitations, it is not possible to fill the carpules nested in the common carrier with sufficient accuracy. This is because the previously used optical control near the narrow opening is not possible for containers in the carrier due to space constraints, and furthermore, the requirements for cleanability and sterilizability cannot be met. Measurements must therefore be taken from a distance with reduced accuracy.

[0009] There are also conventional devices in which a pre-crimped carpule is filled through the opening into which the plug element is later inserted. However, it must be ensured that the fill level is precisely maintained so that the plug element can be placed in the correct target position. DE 102012 207 587 A1 describes a device for filling a carpule. Using an optical sensor device arranged at a distance from the carpule, the fill level of the product in the carpule can be determined.

[0010] An optical sensor device is also used in a device for filling cartridges, which is described in WO 2023 / 174645 A1. Here, several cartridges are accommodated in a common carrier, designed as a nest. The cartridges are already crimped and arranged with the crimped end at the bottom of the carrier. Thus, the only option is to fill the cartridge via the end where the plug element will be inserted at a later time. The optical

[0011] The sensor device is positioned laterally next to the carrier, thus maintaining a large distance from the containers. However, this large distance proves to be disadvantageous because the measurement is not performed at the filling point. Component tolerances, inadequate positioning of the sensor device, and interference factors such as vibrations of the equipment during measurement and / or gas flow in the working chamber (e.g., laminar flow) can distort the results.

[0012] If the fill level is determined solely based on the filled volume, tolerances mean that the accuracy required in practice, for example, of approximately 0.5 mm to 0.6 mm of the fill level, as shown 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%.

[0013] CN 102 944286 A describes a device with which the fill level of a product in a container can be determined capacitively.

[0014] However, the present invention is not limited to applications with containers in the form of carpules. 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 merely as examples to explain considerations that may underlie the present invention.

[0015] Position and orientation specifications, such as "bottom," "top," or the like, refer to the intended use of the device and system, as well as the intended performance of the method. In this case, the filling needle is inserted into the container from above through the insertion opening to dispense the product.

[0016] The object of the present invention is to provide a generic device with which a higher accuracy can be achieved in determining the fill level of the product in the container, preferably with a structurally simple design, in particular with regard to the subsequent setting of a plug element in or on the container.This object is achieved according to the invention in a device of the type mentioned at the outset in 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 and an evaluation unit coupled to the electrodes, wherein at least one of the electrodes can be introduced 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 terminate the filling process.

[0017] In the device according to the invention, an electrical sensor device 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 device can be designed in particular as a capacitive and / or conductive sensor device. The sensor device 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 as a result of the product. When the container is filled with the product, a change in the property can be recorded via the electrodes and determined by the evaluation unit. The evaluation unit can in particular detect or determine a measurement signal that is indicative of the fill level.Once a desired target fill level is reached, a stop signal can be sent directly or indirectly, e.g., via a control device, to a dosing device, which then feeds the product to the filling needle. As practice has shown, 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 measuring process that would otherwise be required, as well as any subsequent transport of the container.

[0018] A particularly advantageous feature of the present invention is that it allows high measurement accuracy to be achieved while maintaining a structurally simple design. The invention is suitable not only for individual processing of containers, containers in a circulating transport system or in a rake transport system, but preferably also for filling containers in a common carrier (for example, in a nest). In particular, it is possible to fill carpules via the end into which the plug element is inserted. The required installation space for the at least one electrode within the container can, as has been shown in practice, be kept so small that it is possible to insert the filling needle and at least one electrode into the carpule.

[0019] The fill level can, for example, be determined relative to a reference position, or it can be ensured that the container is filled to a target fill level that is a specified distance from a reference position. This reference position can, for example, be specified by a position of the container. It is, for example, the section at which the container is hinged or, for example, supported on a support element or plunger. The support element or plunger can, for example, be a lifting element via which the container can be lifted in the direction of the filling needle device. Referencing can, for example, occur during and / or by lifting.

[0020] It is conceivable, for example, that when filling cartridges, an already crimped end of the cartridge is selected as the reference position, so that with the correct target fill level, a target position of the plug element can be maintained if this target position is important for the intended use (as explained above using the example of insulin pens).

[0021] It is particularly conceivable that the at least one electrode in the container can be arranged or aligned relative to the reference position. For example, the electrode is arranged in a position using an adjustment device, with the adjustment device being calibrated relative to the reference position.

[0022] It is also advantageous that a measurement in the container itself is more accurate than that obtained using sensor devices arranged outside the container, as described above. If, for example, the fill level fluctuates due to movement of the container or due to the surface tension of a liquid product, optical sensor devices will provide incorrect fill level readings. This can be avoided with the invention. Furthermore, the measurement is carried out inside the container directly at the product. There is no longer any need to arrange the sensor device at a distance from the actual measuring position. Potential interference factors, such as inadequate positioning of the sensor device, influences from vibrations or from a gas flow in the working chamber, are thus minimized, which ultimately enables a more precise measurement. In this case, the dosing device can be or comprise a pump device.For example, the use of a peristaltic pump is conceivable.

[0023] The evaluation unit can be part of a control device of the device or a control device of the system. Conversely, the evaluation unit can form the control device of the device or the control device of the system.

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

[0025] At least one adjustment device can be provided to insert the filling needle and the at least one electrode into the container. Separate adjustment devices are conceivable, which can be operated synchronously with each other 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 is held or arranged on the filling needle device in a defined, in particular unchangeable, spatial relationship to the filling needle and can be inserted into the container with the filling needle, and / or if one electrode is formed by the filling needle. This enables a structurally simple design with a preferably compact construction. At least one electrode can be inserted into the container together with the filling needle. For this purpose, for example, a common adjustment device can be used, and separate adjustment devices can be omitted. The filling needle itself can, for example, form the first electrode. A pair of electrodes separate from the filling needle can thus be eliminated.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 a defined target position relative to the filling needle in the container. In practice, for example, it has been shown that when the filling needle is used as an electrode, significant changes in the measurement signal can be detected when the product level reaches the filling needle. These significant changes can be reliably detected by the evaluation unit, ensuring the required accuracy in determining the fill level.

[0027] It can be advantageous if both electrodes can be inserted into the container.

[0028] It may prove advantageous, for example, if the first electrode and the second electrode on the filling needle device are held or arranged in a defined, in particular fixed, spatial relationship to the filling needle. In particular, this allows both electrodes to be inserted into the container to achieve the highest possible measurement accuracy.

[0029] In one embodiment of the invention, it can be provided that an electrode is formed by a component of the container to be filled, in particular by a closure element arranged on a side of the container facing away from the insertion opening. For example, when filling crimped cartridges, it is conceivable that the crimp cap is used as a counter electrode to an electrode arranged in the container (e.g., the filling needle).

[0030] It is conceivable that an electrode is formed separately from the container. For example, an electrode can be arranged laterally next to the container or can be a sleeve or tube that is arranged outside the container and at least partially surrounds it. The container can, for example, be pushed into the sleeve or tube.

[0031] 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 of the filling needle. Furthermore, the second electrode is advantageously a sleeve or comprises a sleeve that surrounds the tube. This ensures a structurally simple design combined with a compact construction. If the tube is the filling needle or part of the filling needle, the sleeve preferably also serves as a needle guard. The filling needle device thus has a more robust design.

[0032] The filling needle or tube can be designed to protrude beyond the sleeve, relative to the direction of insertion 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 configuration can prove advantageous, for example, for measurements on liquids with relatively low conductivity, such as water or aqueous liquids.

[0033] Alternatively, the sleeve can extend beyond the filling needle or tube, relative to the direction of insertion into the container. In this case, the sleeve is closer to the fill level than the filling needle or tube. Such a design, as has been shown in practice, is advantageous, for example, for liquids with comparatively high conductivity and can, for example, prove advantageous for measurements on insulin for insulin cartridges. Furthermore, it has been shown in practice that such a design can be used more universally than the embodiment in the previous paragraph. For example, this design can also be used for water or aqueous liquids.

[0034] The sleeve can comprise or form at least one tip at its end, on the side facing the product when inserted. A relatively high local field strength can be achieved via the tip, for example, for capacitive measurements. This can prove advantageous for precise measurements. Furthermore, drops of a liquid product can be more easily released from the sleeve if it is immersed in the liquid during filling. This can be the case, for example, with the aforementioned design, in which the sleeve protrudes beyond the filling needle or tube.

[0035] Two opposing tips can be provided, between which preferably concave recesses, for example in U-shape, are formed on the sleeve.

[0036] The filling needle device preferably comprises an electrical insulation element arranged between the tube and the sleeve and extending at least partially along an extension of the tube and the sleeve. Accordingly, in a preferred embodiment, the insulation element can be arranged between the filling needle, if it forms an electrode, and the sleeve. For example, the insulation element is sleeve-shaped. The insulation element can, for example, extend approximately over at least half the extension of the filling needle and the sleeve.

[0037] For example, the insulation element extends to a respective lower end of the tube and the sleeve, which faces the product, or close to this respective end. The insulation element can also perform mechanical functions of the filling needle device. For example, the insulation element comprises a contact flange and, via this, rests directly or indirectly on a holding body of the filling needle device, wherein the insulation element can form a contact element on which the filling needle rests with a base body that is fluidly connected to the tube. In this way, the filling needle can be reliably held on the holding body. It is conceivable for the insulation element to rest indirectly on 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 bush-shaped, with the tube being inserted into the base body.A connecting element for connecting a supply line, in particular a flexible hose line, can be formed on the base body.

[0038] The holding body can, for example, comprise or form a concave receptacle into which the base body is inserted. The base body can form a contact flange and, via this flange, rest against an edge of the receptacle.

[0039] Alternatively or additionally, a concave receptacle for the aforementioned protective element can be arranged or formed on the holding body. The protective element can, for example, comprise a contact flange that rests against an edge of the receptacle, with the insulating element being supported by the contact flange on the protective element.

[0040] It can be provided that the insulation element contacts the pipe on an inner circumferential surface and / or the sleeve on an outer circumferential surface and / or that spacers are arranged or formed on the insulation element, via which at least one intermediate space is formed between the insulation element and the sleeve and / or between the insulation element and the pipe. For example, the insulation element bears against the pipe on the inner circumferential surface and is supported on the sleeve via the spacers. Alternatively, it can be provided, for example, that the insulation element bears against the sleeve on the outer circumferential surface and is supported on the pipe via the spacers. A gas, in particular compressed air or nitrogen, can flow between the insulation element and the sleeve and / or between the insulation element and the pipe via the at least one intermediate space.By applying gas, for example, drops of a liquid product can be blown off, which may cling to the sleeve and / or tube as a result of the filling needle device being immersed in the product. This serves, on the one hand, to improve the measurement of the fill level.

[0041] Adhering liquid is preferably blown off, preventing it from dripping outside the container. Alternatively, the filling needle device can be moved away from the container via a transport device into a cleaning position, or can assume a cleaning position to blow off adhering liquid.

[0042] In one embodiment of the invention, a protective gas such as nitrogen can be introduced into the container during the filling process to protect the product from oxidation. The protective gas can be supplied, for example, through the aforementioned gap.

[0043] The filling needle device can comprise a holding body on which the filling needle and the sleeve are held, and a connecting element for a supply line arranged on the holding body, wherein the connecting element is in flow connection with the at least one intermediate space. A gas supply device can be arranged on the connecting element via the supply line, whereby the at least one intermediate space can be supplied with gas.

[0044] To provide the flow connection, a flow channel can be formed in the holding body, for example, which opens directly or indirectly into the at least one intermediate space for supplying the at least one intermediate space 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, in turn, can have a through-opening. The through-openings can be aligned. Gas flows, for example, through the holding body, the protective element, and the sleeve into a space between the sleeve and the insulation element.

[0045] 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, whereby two or more containers can be filled via the filling needles. Accordingly, the filling needle device can be designed with multiple positions. Each of the containers can be filled via a filling needle. Not only a two-position design is conceivable, but more filling needles can also be present. For example, it can be provided that there are enough filling needles that at least one row of a common container support can be filled, preferably two rows.

[0046] It goes without saying 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 identically and can form a filling unit. The receptacles can be identical.

[0047] The two or more filling needles can be assigned a common connection element for the supply of gas. A flow channel in the base body can branch to allow gas to flow to a respective intermediate space.

[0048] Advantageously, the sensor device comprises two or more first electrodes and second electrodes, wherein a first electrode and a second electrode are assigned to a respective filling needle, wherein a measurement signal indicative of the fill level of the product in the respective container can be detected or determined by the evaluation unit during filling of the respective container, and wherein a stop signal can be provided directly or indirectly to a dosing device to terminate the filling process. In a multi-position design, it is accordingly advantageously possible to determine the fill level on 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 device.

[0049] Advantageously, each filling needle is assigned a dosing device so that the supply of the product to each filling needle can be started and / or stopped separately and thus dosed separately.

[0050] The aforementioned holding body can comprise or form a respective holding area on which a respective filling needle is held. The holding area comprises, for example, at least one receptacle for the base body and / or for the protective element.

[0051] A holding area is formed, for example, on a projection of a housing of the holding body, wherein the filling needle is arranged on the side of the projection facing away from the housing, and wherein a recess is formed laterally next to the projection, in which the other filling needle is arranged. This makes it possible, for example, to achieve 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 (for example, a nest) that are positioned in successive rows of the carrier. Containers in successive rows are usually arranged staggered relative to one another.In a structurally simple embodiment of the invention, the filling needle device can comprise two electrodes that are formed separately from the filling needle and are secured to the filling needle or to a sleeve surrounding the filling needle via at least one retaining element. For example, separate electrodes are secured to the outside of the filling needle or the sleeve.

[0052] The electrodes can be printed as electrical conductors on a preferably flexible holding element. The holding element can, for example, be attached to the outside of the filling needle or to a sleeve surrounding the filling needle.

[0053] Alternatively, the electrodes can be printed as conductor tracks on the filling needle device, for example on the sleeve or the tube.

[0054] For example, 3D printing can be used to print the circuit tracks.

[0055] Continuous detection or determination of a measurement signal by the sensor device can be provided.

[0056] Alternatively, the sensor device may be designed to detect or determine the measurement signal at intervals.

[0057] As already mentioned, the sensor device is designed electrically, in particular capacitively and / or conductively.

[0058] It is conceivable that the evaluation unit provides an electrical voltage between the first electrode and the second electrode for a capacitive and / or conductive measurement and that a change in the voltage and / or a change in the current flow between the electrodes can be detected as a result of a changing distance between the at least one electrode in the container and the further electrode. For example, an alternating voltage is applied across the electrodes. The voltage can be 10 VAC, for example, and a frequency of the alternating voltage can be approximately 10 kHz to 200 kHz, for example. An electric field can change as a result of the changing fill level of the product, in particular a liquid. In practice, a significant change in the electric field is detected in a capacitive measurement, for example when an electrode comes into contact with the product or is immersed in it.The corresponding measurement signal can be reliably detected by the evaluation unit. A change in the measurement signal can, for example, be a significant increase in the measurement signal. Conversely, a change in the measurement signal can be a significant decrease in the measurement signal.

[0059] It goes without saying that calibration of the sensor device can and should be performed depending on the product to be filled and / or the container. This offers the possibility of reliably generating suitable measurement signals with a view to determining the fill level as reliably as possible.

[0060] The filling needle or electrode may be designed to be immersed in or in contact with the product. Alternatively, it may be designed so that contact or immersion is not required.

[0061] During operation of the device, the filling needle can be inserted into the container, for example, via an adjustment device. The adjustment path can be specified so that the target fill level is reached when the filling needle or tube touches or dips into the product. Feedback can be provided if the measurement signal indicates that the desired target fill level is not reached when the filling needle or tube touches or dips into the product.

[0062] The system according to the invention for processing containers, in particular pharmaceutical containers, comprises at least one processing station for processing the containers, which comprises 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 adjusting 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 terminate the filling process,when the fill level of the product in the container reaches a specified target fill level.

[0063] "Coupling the sensor device with the control device" can, in this case, mean that the evaluation unit of the sensor device is part of the control device or that the evaluation unit forms the control device. 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 above 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 above explanations.

[0064] If the filling needle device in a multi-position configuration comprises two or more filling needles, the system advantageously includes two or more dosing devices, with each filling needle being assigned a dosing device. This allows individual filling via each filling needle. The fill level of each container can preferably be determined separately via the evaluation unit.

[0065] It is conceivable that the filling needle device for filling the container is stationary and that at least one container is moved via the adjusting device.

[0066] Alternatively, it can be provided that the at least one container is stationary, wherein the filling needle device is moved via the adjusting device.

[0067] Alternatively, it is conceivable that both at least one container and the filling needle device are moved.

[0068] The at least one adjusting device can, for example, be or comprise a lifting device that includes a lifting element by means of 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.

[0069] The at least one adjusting device can be or comprise a lifting device by means of which the filling needle device can be lowered in the direction of the container.

[0070] As already mentioned, it can be provided that a separate adjusting device is used for the at least one electrode, which can be or comprise a lifting device. It can be advantageous if at least one electrode is held or arranged on the filling needle device or if the filling needle forms an electrode. In this way, one adjusting device can be saved. For nested containers, for example, it is advantageous if the system comprises a handling device for handling, in particular transporting, a carrier for a plurality of containers and if at least one container can be lifted at least partially out of the carrier in the direction of the filling needle device via the lifting device. In this way, containers can be processed in the carrier. These containers are, for example, flanged carpules that are filled via the insertion opening into which the plug element is placed at a later time.It is particularly conceivable for two or more containers to be filled simultaneously. For this purpose, the filling needle device can have multiple filling needles, as already described. Advantageously, filling in rows and / or filling containers in two or more rows is possible.

[0071] The system may be free of an optical sensor device for controlling the fill level, at least at the filling station.

[0072] The containers can be pre-crimped carpules, wherein a pre-crimped end of the carpule is arranged at the bottom in the carrier and the insertion opening for inserting a plug element is provided at the top.

[0073] The system can preferably include a testing station with which the container can be checked to determine whether the fill level corresponds to the target fill level. The testing station is used, for example, during the system's teach-in or run-in phase at the start of a production process and is used, for example, for the purpose of calibrating the sensor device and / or the at least one adjustment device and / or for checking machine settings. This ensures that the actual production process runs as error-free as possible by reducing the reject rate of insufficiently filled containers. The check can be carried out randomly or, for example, for a predefined number of containers.

[0074] For example, the filled container can be transported to the inspection station via a transport device (e.g., a robotic transport device) and, after inspection, transported back to the filling station or to a closing station. For example, the container can be removed from a common carrier and reinserted into it.

[0075] The system can preferably comprise a closing station downstream of the filling station in a processing direction. 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 using the device according to the invention, it is also possible to position the plug element as desired at the defined target position.

[0076] The plug element is inserted into the container, for example, using a vacuum plug insertion system, 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.

[0077] A target position of the plug element can be determined in particular with respect to the reference position mentioned above.

[0078] If the containers are arranged in a common carrier, they are closed, for example, while they are in the carrier.

[0079] It can be provided that the container can be checked using the aforementioned test station to determine whether the position of the stopper element corresponds to the target position. For example, during system setup or commissioning at the beginning of a production process, after the filling station check and the container closure, the position of the stopper element is checked to ensure the most error-free process flow possible. The check can be performed randomly or, for example, for a specified number of containers.

[0080] For transporting the sealed container, the aforementioned transport device can be used, for example. The container can be removed from and reinserted into a common carrier.

[0081] 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 teach-in or run-in, the fill level and / or the height of the plug element can be checked, for example.

[0082] The at least one processing station can comprise a further filling station which is arranged upstream of the filling station in a processing direction of the system, wherein the containers are pre-filled with the product up to a first fill level at the further filling station and filled up 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 volume flow. For example, filling needles with a larger diameter can be used here than at the filling needle device. In practical applications, for example, filling needles with an inner diameter of approximately 2 to 3 mm can be used (for example for filling quantities of approximately 2 to 5 ml), wherein 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 needle device, compared to the first filling needle, is advantageous because only a small volume flow is achieved, allowing the filling process to be completed precisely. The smaller diameter is also advantageous because it provides space for the electrode, which is to be inserted into the container. During prefilling, the container can be partially filled relatively quickly, for example, from approximately 70% to approximately 95%. Using the device according to the invention, the remaining product is filled up to the desired fill level.

[0083] It is understood that the dimensions 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.

[0084] The dosing device can preferably be used to determine which quantity of product is being filled in order to fill the containers from the first fill level up to the target fill level. Depending on the determination, a dosing device at the further filling station can be controlled to pre-fill a larger or smaller quantity of product to achieve a higher first fill level or a lower first fill level. This makes it possible to optimize the functioning of the system. For example, there can be feedback between the two filling stations, with the respective fill levels being adjusted automatically. If the first fill level is too low, the cycle time can be increased by filling more product during pre-filling. If, on the other hand, the first fill level is so high that the accuracy of determining the target fill level may suffer, less product can be pre-filled.

[0085] The system may comprise a gas supply device coupled to the control device, which is in fluid communication with the connection element on the holding body via a supply line. The gas supply device can be selectively activated to supply the filling needle device with gas. This allows any drops of product to be blown off the filling needle device.

[0086] The system can comprise a transport device coupled to the control device, by means of which the filling needle device and the container can be selectively moved relative to one another, wherein the gas supply device can be activated when the filling needle device has a cleaning position relative to the container. For example, the filling needle device can be moved sideways relative to the container and blown off in a cleaning position there. Alternatively, it can be provided that the container moves relative to the stationary filling needle device, which consequently assumes a cleaning position to blow off liquid.

[0087] It is understood that the gas supply device may, for example, comprise a valve element to selectively open or close the supply line.

[0088] Automated calibration of the adjustment device can be provided to ensure the most suitable target position of the filling needle device 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 device relative to the container. If necessary, a preferably dynamic adjustment of the adjustment device can be performed during system operation to change the relative position for setting the fill level.

[0089] 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 a system of the type described above comprises:

[0090] Inserting the filling needle device into the container via an insertion opening; as part of the filling needle device or separately therefrom, inserting at least one electrode into the container;

[0091] Activating the dosing device after or during insertion; detecting or determining a measuring signal indicative of the fill level of the product in the container; and

[0092] Providing a stop signal directly or indirectly to the dosing device to terminate the filling process when a target fill level is reached.

[0093] The advantages and effects already mentioned in connection with the explanation of the device and the system according to the invention can be achieved by implementing 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.

[0094] The method is particularly suitable for filling containers in a common carrier, in particular flanged carpules, wherein the insertion opening is the opening through which a plug element is inserted at a later time.

[0095] However, as already mentioned, the present invention is not limited to such an application and to such a type of system.

[0096] The following description of preferred embodiments of the invention, taken in conjunction with the drawings, serves to explain the invention in more detail. They show:

[0097] Figure 1: a schematic representation of the system according to the invention in a preferred embodiment;

[0098] Figure 2: a schematic view of a part of the system, showing a carrier with several containers and a filling needle device for filling the containers;

[0099] Figure 3: a schematic representation of a filling needle device (partial view) and a container at the beginning of a filling process;

[0100] Figure 4: a representation corresponding to Figure 3 at the end of the filling process;

[0101] Figure 5: an enlarged view of detail A in Figure 3 and an evaluation unit for explaining a measuring principle in the device according to the invention; Figure 6: the filling needle device (partial view) and the container as well as an evaluation unit for explaining the measuring principle in the device according to the invention;

[0102] Figure 7: a perspective view of a filling needle device of the device according to the invention in a preferred embodiment, partially in section;

[0103] Figure 8: the filling needle device from Figure 7, partially as an exploded view;

[0104] Figure 9: a plan view of the filling needle device from Figure 7;

[0105] Figure 10: a sectional view taken along line 10-10 in Figure 9;

[0106] Figure 11: several diagrams as a function of time to explain the measuring principle of the device according to the invention;

[0107] Figure 12: a representation corresponding to Figure 11, obtained when filling a different type of product;

[0108] Figure 13: a representation corresponding to Figure 11 , obtained using a variant of the measuring principle;

[0109] Figure 14: schematically shows part of a variant of the filling needle device of the device according to the invention;

[0110] Figure 15: schematically shows part of a variant of the filling needle device of the device according to the invention; and

[0111] Figure 16: schematically shows part of a variant of the filling needle device of the device according to the invention.

[0112] Figure 1 shows a schematic representation of an advantageous embodiment of the system according to the invention, designated overall by the reference numeral 100, for processing, in particular, pharmaceutical containers that are filled with, in particular, a pharmaceutical product. The product is, in particular, liquid. The invention is explained below using the example of containers 102 in the form of carpules 104, but is not limited to the filling of carpules 104. Furthermore, to explain the invention, it is assumed here by way of example that the carpules 104 are accommodated in a common carrier 106, designed as a nest 108 (Figure 2). The nest 108 is inserted into a tub 109.

[0113] During intended use, the carpules 104 in the present example are accommodated in the nest 108 such that a first end 110, to which a crimp cap 112 is attached, is located at the bottom. An opposite second end 114 is located at the top. An insertion opening 116 is formed at the second end 114. The insertion opening 116 in the carpule 104 has a larger cross-section than an opposite opening 118 at the first end 110.

[0114] In the present example, the system 100 comprises a supply station 120, at or via which the nests 108 are provided. Downstream in a 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 dosing device 124 and a filling needle device 126 with one or more filling needles.

[0115] Alternatively, the product can be non-liquid, for example, a powder.

[0116] The system 100 comprises a control device 128 with which the operation of the system 100 can be controlled and / or regulated. The control device 128 is coupled to the dosing device 124 and a transport device for moving the filling needle device 126 and the containers 102 relative to one another.

[0117] At the filling station 122, the containers 102 are partially filled until the product in the container 102 reaches a first fill level 130. For this purpose, the filling needles of the filling needle device 126 can have a comparatively large cross-section in order to provide a high volume flow to achieve a high cycle time of the system 100.

[0118] The system 100 further comprises a further 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 comprises a filling needle device 136 and a sensor device 138. The sensor device 138 can, for example, be partially (for example 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, 138 are shown separately in Figure 1. Conversely, the sensor device 138, for example its evaluation unit, can form the control device 128.

[0119] The filling station 132 further comprises a dosing device 140, which is coupled to the control device 128. If the sensor device 138 is separate from the control device 128, these devices 128, 138 are coupled to one another.

[0120] Furthermore, the system 100 comprises a gas supply device 142 for providing a gas, for example compressed air and / or nitrogen.

[0121] At least one adjusting device 144, 145 is arranged at the filling station 132, in the present case each designed as a lifting device 146 (Figure 2).

[0122] Downstream of the filling station 132 in a processing direction, the system 100 comprises a closing station 148. After the containers 102 have been filled with the product at the filling station 132 up to a desired fill level 166, they can be closed at the closing station 148 using plug elements 150. 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.

[0123] To ensure that the stopper element 150 is located at a precisely defined target position, it is important to ensure that the container 102 is filled to the specified target fill level 166. When used as intended, the stopper element 150 serves as a stop element for a product dispensing device.

[0124] This applies, for example, to delivery devices in the form of injection pens, where the carpules 104 contain insulin. Reliable plug element positioning is necessary to ensure the function of the insulin pen and the amount of insulin delivered. The target position of the plug element 150 can be determined relative to a reference position, for example, the end 110 of the carpule 104.

[0125] The system 100 can have a Kontra II station 152 downstream of the closing station 148. At the control station 152, the fill level and the position of the plug element 150 and, for example, the general proper condition of the containers 102 can be checked using optical sensors, for example. Defective containers 102 can preferably be sorted out. Reference numeral 154 designates a handling device of the system 100, in particular to ensure the transport of the nests 108 within the system 100 as a transport device. It is understood that the handling device 154 can be controlled by the control device 128 and can comprise several individual components for respective transport sections.

[0126] As can be seen from Figure 2, for example, the filling needle device 136 can comprise 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 device 136 comprises enough filling needles 158 to be able to fill at least one row 160 simultaneously. The filling needle device 136 can accordingly be designed with multiple positions.

[0127] The system comprises a dosing device 140 associated with each filling needle 158. This allows each container 102 to be filled individually.

[0128] The specific method of securing the filling needle 158 to the holding body 156 is not shown in Figure 2. A preferred embodiment of the filling needle device 136, explained below with reference to Figures 7 to 10, shows detailed features in this regard. For the purposes of explaining the invention, this method of securing is not absolutely necessary.

[0129] The lifting device 146 is used to fill the containers 102. The lifting device 146 comprises a drive unit 162 and a lifting element 164, which can be a ram, associated with each container 102 to be lifted. When the respective container is to be filled, the drive unit 162 is activated, and the container 102 is lifted, as shown in Figure 2 by way of example for two (or two rows) of containers 102.

[0130] The filling needle device 136 can be lowered via the further adjustment device 145.

[0131] Due to the relative movement of the container 102 and the filling needle device 136, the filling needle device 136 engages, as explained below, at least partially into the container 102 via the insertion opening 116. The filling needle 158 and the electrodes 178, 180 are arranged in the container 102. For electrodes that are not held on the filling needle device 136 or are formed by the filling needle, a separate adjustment device can be used, for example.

[0132] 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, the filling process can be provided to begin during insertion.

[0133] For the intended use of the carpules 104, the target fill level 166 is set relative to a reference position. In this case, the reference position is the lower end 110 of the carpule 104, at which the crimp cap 112 is arranged and via which the carpule 104 is supported on the lifting element 164.

[0134] The fill level can be measured when filling the container 102.

[0135] When the product fill level in container 102 reaches the desired target fill level 166, the filling process is terminated. Container 102 is then lowered again via the lifting device 146. Additional containers 102 can be filled. Once all containers 102 of nest 108 are filled, nest 108 is transported to closing station 148 to insert plug elements 150. Alternatively, closing station 148 can insert plug elements 150 while additional containers 102 of nest 108 are still being filled.

[0136] The plug elements 150 are inserted into the containers 102 via vacuum plug insertion, up to the target fill level 166 with no air bubble or only a very small air bubble. In this way, the position of the plug element 150 is influenced by the fill level.

[0137] The dosing device 140 can preferably be used to determine the quantity of product being filled to fill the container 102 from the first 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 the purpose of prefilling, prefilling a larger or smaller quantity of product for a higher first fill level or a lower first fill level, respectively. For example, if a relatively large quantity of product is to be filled via the dosing device 140, the fill level at the filling station 122 can be increased to raise the first fill level 130. This is advantageous, for example, 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, proceeds more slowly than at the filling station 122.

[0138] If, on the other hand, the quantity of product to be filled at the filling station 132 is relatively small and / or the target fill level 166 can only be measured imprecisely, the dosing device 124 can be controlled to implement a lower fill level during prefilling. This can be the case, for example, if the first fill level 130 is close to or very close to the target fill level 166.

[0139] It is understood that the adjustment described above is possible during ongoing operation of the system 100.

[0140] The measuring principle of the device 134 according to the invention is explained below, in particular with reference to Figures 2 to 6.

[0141] The filling needle device 126 has at least one filling needle 158. In the present case, the filling needle 158 comprises a base body 168, which is designed as a bushing 170. The filling needle 158 further comprises a tube 172, which is fluidly connected to the base body 168. A connecting element 174 for connecting a supply line for the product delivered by the dosing device 140 is arranged on the base body 168. The dosing device 140 is, for example, a peristaltic pump.

[0142] The filling needle device 136 further includes 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 coaxially aligned with each other.

[0143] The sensor device 138 is an electrical sensor device and, in this case, is designed for capacitive measurement. This is evident from Figures 5 and 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.

[0144] The sleeve 176 is held in a defined and, in particular, unchanging relationship relative to the filling needle 158 on the filling needle device. As a result, the spatial relationship between the electrodes 178, 180 remains unchanged before, during, and after the filling process. This ensures consistently reliable measurement conditions.

[0145] An electrical insulation element 182 is arranged between the electrodes 178, 180. The insulation element 182 is designed as a sleeve 184, the inner circumferential surface of which rests against the outside of the tube 172 (Figures 3 and 4). The sleeve 184 electrically insulates the electrodes 178, 180 from each other.

[0146] The sleeve 184 can form a contact flange 186, which in the present example abuts against a protective element 190, also designed as a sleeve 188. The protective element 190 surrounds the sleeve 176 in sections in the area that cannot be inserted into the container 102. For example, the sleeve 188 can form a contact flange for abutting against the holding body 156.

[0147] The filling needle 158 can, for example, be held on the holding body 156 via the base body 168.

[0148] In the embodiment of the filling needle device 136 shown in Figures 2 to 7, the tube 172 extends beyond the sleeve 176 relative 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 contacts the liquid.

[0149] Such a design proves to be suitable, for example, for measuring fill levels, particularly for liquids with low conductivity, such as water or water-containing substances.

[0150] The electrodes 178, 180 are connected via electrical lines 194 to a voltage source 196 of the evaluation unit 198 of the sensor device 138. A current measuring device 200 can, for example, be connected to one of the lines 194. An electrical potential difference existing between the electrodes 178, 180 can be set or maintained via the voltage source 196. For this purpose, a current can flow through the current measuring device 200 when the electric field changes. This current can, provided the sensor device 138 is appropriately calibrated, be indicative of a fill level of the liquid in the container 102. Accordingly, a measurement signal indicative of the fill 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 device 128 (arrow 202).Based on this, the control device 128 can deactivate the dosing device 140 when the target fill level is reached.

[0151] Figure 5 schematically shows how the liquid is filled into the container 102 starting from the first fill level 130. The amount of product filled via the filling station 132 is schematically indicated in Figure 5 by densely dotted areas 204.

[0152] In the present example, the device 134 is calibrated so that the fill level corresponds to the target fill level 166 when the tube 172 of the filling needle 158 just contacts the liquid. Reference numeral 206 schematically shows the electric field between the electrodes 178, 180. This field changes significantly, as is apparent in practice, when the target fill level 166 is reached.

[0153] 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 can be provided that the sleeve 176 is at ground potential (GND) and the tube 172 is at a correspondingly increased potential.

[0154] The evaluation unit 198 can comprise an amplifier unit 210, comprising, for example, an operational amplifier, downstream of the current measuring device 200.

[0155] 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.

[0156] Figure 11 illustrates several curves during the operation of system 100 (ordinates) as a function of time (abscissa). The process is shown here for filling a container 102.

[0157] A dashed line 214 shows the relative position of the filling needle 158 and the container 102 as a function of time (with the reversed ordinate). At the initial time t0, the filling needle device 136 is immersed in 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 arranged in the container 102. Once a target position is reached at a second time t1, the filling process is started by activating the dosing device 140. A dash-dotted line 216 symbolically represents the working cycle of the peristaltic pump of the dosing device 140.

[0158] A solid line 218 represents the measurement signal from 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 a time t2, the measurement signal suddenly increases significantly. 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 tube 172 touches the liquid.

[0159] A horizontal dash-dotted 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.

[0160] A dotted line 224 schematically represents a stop signal for stopping the dosing device 140.

[0161] A dashed line 226 symbolizes the machine cycle of system 100.

[0162] It can be seen that after the dosing device 140 is switched off, the container 102 is again moved relative to the filling needle 158, in particular, it is lowered. This can be seen from line 214. It can also be seen that the measurement signal 218 drops sharply during this movement.

[0163] As a result, the exemplary measurement curves according to Figure 11 illustrate that the target filling level 166 can be reliably determined.

[0164] While Figure 11 shows the check based on a rising edge of the measurement signal 218, Figure 12 shows a representation of measurement curves recorded during the filling of a different product. A total of four cycles are shown as a function of time, i.e., the measurement curves extend over the time required to fill four containers 102.

[0165] It can be seen that the measurement signal 218 already rises sharply at the beginning of the filling process and then continues to rise. Subsequently, a falling edge can be seen, during which the measurement signal 218 drops sharply at time t2. This is considered to indicate that the target fill level 166 has been reached. The dosing device 140 is deactivated at this time, as can be seen from the dotted line 224.

[0166] In the examples of Figures 11 and 12, the sensor device 138 is operated capacitively.

[0167] Figure 13 shows an example of the sensor device 138 being used in conductive operation using measurement curves. It can be seen that some time after the start of the filling process, the measurement signal 218 suddenly increases. This is considered to indicate that the target fill level has been reached. When this sharply rising edge occurs, the dosing device 140 is deactivated, as indicated by the dotted line 224.

[0168] The exemplary representations in Figures 12 and 13 also show that the device 134 according to the invention reliably detects when the target fill level 166 has been reached. If this is the case, the filling process is terminated.

[0169] In particular, it is shown that the required accuracy can be achieved in order to be able to insert the plug element 150 into the container 102 with the required accuracy.

[0170] The embodiment of the filling needle device 136, which is shown in Figures 2 to 6 and in which the tube 172 projects beyond the sleeve 176 in the insertion direction 192, proves to be suitable, for example, for measurements on liquids with relatively low conductivity.

[0171] A test station 227 can be used during the teach-in or commissioning of the system 100 (Figure 1). The test station can be used to ensure, before the actual production process, that the target fill level 166 is maintained and that the stopper element 150 is in the correct target position. This ensures that the actual production process runs as error-free as possible by reducing the reject rate of insufficiently filled containers 102. The test can be performed randomly or, for example, for 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 by an operator. This includes, for example, calibrating the sensor device 138 and / or the adjustment devices 144, 145.By means of a transport device (for example, designated by reference numeral 268), the filled container 102 can be transported to the inspection station 227 and, after inspection, placed back into the nest 108. Subsequently, the plug element 150 is inserted and the container is transported again to the inspection station 227 for inspection.

[0172] The following describes an embodiment of the filling needle device 136, which is illustrated in Figures 7 to 10. This embodiment is advantageously suited, for example, for measurements on liquids with higher conductivity, such as insulin. However, it has been shown in practice that this embodiment is also suitable for liquids with lower conductivity and is therefore versatile.

[0173] The filling needle device 136 according to Figures 7 to 10 can be used instead of the filling needle device 136 according to Figures 2 to 6 in the device 134 according to the invention. Identical reference numerals are used for identical or equivalent features and components.

[0174] The filling needle device 136 comprises the holding body 156. A projection 228 is arranged on the holding body 156, on which a holding region 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 region 232 is provided for the filling unit 230 on the projection 228.

[0175] The filling needle device 136 has a further holding area 232. A recess 236 is formed laterally next to the projection 228, in which the second holding area 232 is arranged. A further filling unit 230 is held on the holding area 232.

[0176] Accordingly, the embodiment according to Figures 7 to 10 also has two positions. However, the two filling units 230 are arranged offset or staggered relative to one another, as can be seen particularly from the top view of Figure 9. Thus, when the filling needle device 136 is used, one container 102 of a row 160 and one of an adjacent row 160 of the nest 108 is filled.

[0177] The filling units 230 and the respective configuration of the holding areas 232 are identical, so that only one configuration at a time will be discussed below. A first receptacle 238 is arranged on the holding area 232, which is essentially semi-cylindrical in contour and has an edge 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 bears against the edge 240.

[0178] A second receptacle 244 is formed below the receptacle 238. The second receptacle 244 is also substantially semi-cylindrical in contour and includes an edge 246.

[0179] The protective element 190 is arranged in a form-fitting manner 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 contact flange 186 and, via the latter, against the holding body 156. The base body 168 rests against the sleeve 184.

[0180] The insulation element 182 extends through the sleeve 188. The insulation element 182 rests against the tube 172 on an inner circumferential surface. On the radially outer side, however, a gap 250 is formed between the insulation element 182 and the sleeve 176.

[0181] Spacers 252 are arranged radially on the outside of the insulation element 182, which contact the sleeve 176 on the inside and thereby ensure a reliable fit of the insulation element 182 in the sleeve 176.

[0182] In terms of its longitudinal extent, the insulation element 182 may extend over virtually the entire length of the tube 172 and the sleeve 176, as shown in Figures 7 and 10. For example, the extent is at least approximately half the length of the sleeve 176 and the tube 172.

[0183] At the bottom, the sleeve 176 protrudes beyond the tube 172, relative to the insertion direction 192. At its end, the sleeve 176 has at least one tip 254. In the present case, there are two opposing tips 254. Between each of the tips 254, a concave recess 256 is formed on the sleeve 176, which is U-shaped in the present example.

[0184] A connecting element 258 is arranged on the holding body 156. A supply line 260 can be connected to the connecting element 258 to bring the filling needle device 136 into flow communication with the gas supply device 142. A branching flow channel 262 is formed in the holding body 156 so that incoming gas can flow through the holding body 156 to a respective filling unit 230 (Figure 10).

[0185] For this purpose, a through-opening 264 is formed on the protective element 190, which is aligned with a corresponding through-opening 266 in the sleeve 176. Gas flows through the through-openings 264, 266 into the intermediate space 250 between the sleeve 176 and the insulating element 182. The gas can continue to flow to the lower end of the filling unit 230.

[0186] If the filling unit 230 is 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 provide gas, in particular compressed air or nitrogen, to blow off adhering liquid through the supply line 260, the flow channel 262, and the intermediate space 250.

[0187] It can be provided that the liquid is blown off while the filling unit 230 is still arranged in the container 102. On the other hand, it can be provided that the filling needle device 136 and the containers 102 are moved relative to one another via a transport device 268 until the filling needle device 136 has a cleaning position, in particular outside a region of the containers 102. Liquid can be blown off at a distance from the containers 102.

[0188] During the filling process, a protective gas such as nitrogen can preferably be introduced into the container 102 to protect the product from oxidation. The protective gas can, for example, be supplied via the intermediate space 250.

[0189] A possible multi-position configuration has already been discussed, for example, in connection with Figure 2. 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. Since each filling needle 158 is also 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 arise in the function and quality, for example of the adjusting devices 144, 145. Any component tolerances can also be compensated for by the individual control. Alternatively or additionally, it can be provided that the lifting elements 164 can be controlled individually for each container 102 in order to compensate for mechanical deviations.

[0190] Figure 14 shows a different variant of a filling needle device 136. Electrodes 178, 180 are provided here, which are formed separately from the tube 172 and are, for example, needle-shaped. The electrodes 178, 180 protrude beyond the tube 172 of the filling needle 158.

[0191] The electrodes 178, 180 are fixed to the sleeve 176 or to the tube 172 via two holding elements 270, designed as holding rings in the present example.

[0192] Figure 15 shows a variant of the filling needle device 136, in which the electrodes 178, 180 are printed onto a flexible holding element 272 by means of electrical conductor tracks. The holding 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 downward, for example, beyond the tube 172. The holding element 272 can be secured to the sleeve 176 or to the tube 172.

[0193] Alternatively, the electrodes 178, 180 can be printed by 3D printing, for example onto the sleeve 176 or the tube 172. The holding element 272 can thus be omitted.

[0194] Figure 16 shows another sleeve 274, which could be used, for example, instead of sleeve 176. Unlike the previously described variants, sleeve 274 has only one tip 254. Its lower end is beveled at an angle relative to an axis of sleeve 274. Liquid droplets are also less likely to adhere to sleeve 274, as described in connection with the variant according to Figures 7 to 10. List of Reference Symbols

[0195] Plant Container Carpule Carrier Nest Tub First end Crimp cap Second end Insertion opening Opening Provision station , 132 Filling station , 140 Dosing device , 136 Filling needle device

[0196] Control device first fill level device sensor device

[0197] Gas supply device , 145 Adjustment device Lifting device Closing station Plug element Control station Handling device Holding body Filling needle Row Drive unit Lifting element Target filling level Base body Bushing Tube , 258 Connection element , 184, 188, 274 Sleeve

[0198] electrode

[0199] electrode

[0200] Insulation element, 242, 248 contact flange

[0201] protective element

[0202] Direction of insertion of electrical cable

[0203] Voltage source

[0204] Evaluation unit

[0205] ammeter

[0206] Arrow

[0207] Area electric field

[0208] Coaxial cable

[0209] amplifier unit

[0210] Adjustment element dashed line (relative position of filling needle device and container) dash-dotted line (dosing device) solid line (measurement signal) dash-dotted line

[0211] Threshold dotted line (switching signal) dashed line (machine)

[0212] projection

[0213] Filling unit

[0214] Holding area, 256 Recess, 244 Receptacle, 246 Edge

[0215] space

[0216] spacer

[0217] Great

[0218] supply line

[0219] flow channel

[0220] Through opening Through opening

[0221] Transport facility

[0222] Holding element

[0223] Holding element

Claims

PATENT CLAIMS 1. 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 (130, 166) of the product in the container (102) can be determined, characterized in 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) indicative of the fill level of the product in the container (102) can be detected or determined by the evaluation unit (198) during filling of 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 in that the fill level of the product in the container (102) can be determined relative to a reference position or that it can be ensured that the container (102) is filled up to a desired fill level which has a predetermined distance relative to a reference position.

3. Device (134) according to claim 2, characterized in that the at least one electrode (178, 180) can be arranged or aligned in the container (102) relative to the reference position.

4. Device (134) according to one of the preceding claims, characterized in that at least one electrode (178, 180) is held on the filling needle device (136) in a defined, in particular unchangeable, spatial relationship to the filling needle (158) or is arranged 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).

5. Device (134) according to one of the preceding claims, characterized in 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 unchangeable, spatial relationship to the filling needle (158).

6. Device (134) according to one of claims 1 to 4, characterized in that an electrode (178, 180) is formed by a component of the container (102) to be filled, in particular by a closure element which 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).

7. Device (134) according to one of claims 1 to 5, characterized in 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) which surrounds the tube (172) and is preferably aligned coaxially thereto.

8. Device (134) according to claim 7, characterized in that the filling needle (158) or the tube (172) projects beyond the sleeve (176) or that the sleeve (176) projects beyond the filling needle (158) or the tube (172).

9. Device (134) according to claim 7 or 8, characterized in that the sleeve (176) comprises or forms at least one tip (254) at its end, in particular two opposing tips (254), between which preferably concave recesses (236, 256) are formed on the sleeve (176).

10. Device (134) according to one of claims 7 to 9, characterized in that the filling needle device (136) comprises an electrical insulation element (182) which is arranged between the tube (172) and the sleeve (176) and extends at least in sections along an extent of the tube (172) and the sleeve (176).

11. Device (134) according to claim 10, characterized in that the insulation element (182) comprises a contact flange (186, 242, 248) and rests via this on a holding body (156) of the filling needle device (136) and forms a contact element on which the filling needle (158) rests with a base body (168) which is fluidically connected to the tube (172).

12. Device (134) according to claim 10 or 11, characterized in that the insulation 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 insulation element (182), via which at least one intermediate space (250) is formed between the insulation element (182) and the sleeve (176) and / or between the insulation element (182) and the tube (172).

13. Device (134) according to claim 11 or 12, characterized in that the filling needle device (136) comprises a holding body (156) on which the filling needle (158) and the sleeve (176) are held, and a connecting element (258) arranged on the holding body (156) for a supply line (260), wherein the connecting element (258) is in flow connection with the at least one intermediate space (250).

14. Device (134) according to claim 13, characterized in 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 intermediate space (250) for supplying the at least one intermediate space (250) with gas.

15. Device (134) according to one of the preceding claims, characterized in that the filling needle device (136) comprises two or more filling needles (158) and preferably a holding body (156) to which the filling needles (158) are fixed, wherein two or more containers (102) can be filled via the filling needles (158).

16. Device (134) according to claim 14, characterized in 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 a respective filling needle (158), wherein a measuring 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.

17. Device (134) according to one of the preceding claims, characterized in that the holding body (156) comprises or forms a respective holding region (232) on which a respective filling needle (158) is held, wherein a holding region (232) is formed on a projection (228) of a housing of the holding body (156), wherein the filling needle (158) is arranged on the side facing away from the housing on the projection (228), and wherein laterally next to the projection (228) a recess (236) is formed, in which the other filling needle (158) is arranged.

18. Device (134) according to one of the preceding claims, characterized in 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 holding element (270).

19. Device (134) according to one of the preceding claims, characterized in that the electrodes (178, 180) are printed as electrical conductor tracks on a preferably flexible holding element (272) or on the filling needle device (136).

20. Device (134) according to one of the preceding claims, characterized by a continuous detection or determination of a measurement signal (218) or by a detection or determination of the measurement signal (218) at time intervals by the sensor device (138).

21. Device (134) according to one of the preceding claims, characterized in 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 the voltage and / or a change in a current flow between the electrodes (178, 180) can be detected.

22. System (100) for processing containers (102), in particular pharmaceutical containers (102), comprising at least one processing station for processing the containers (102), which comprises a filling station (122, 132), wherein the filling station (122, 132) comprises a dosing device (140) and a device (134) according to one of the preceding claims, a control device (128) coupled to 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 during operation of the system (100) the filling needle (158) and the at least one electrode (178, 180) via the insertion opening (116) is introduced into the container (102), 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 terminate the filling process when the fill level of the product in the container (102) reaches a predetermined target fill level (166).

23. System (100) according to claim 22, characterized in that the at least one adjusting device (144, 145) is or comprises a lifting device (146) which comprises a lifting element (164) via 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) via which the filling needle device (136) can be lowered in the direction of the container (102).

24. System (100) according to claim 23, characterized in that the system (100) comprises 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 out of the carrier (106) in the direction of the filling needle device (136) via the lifting device (154).

25. System (100) according to one of claims 22 to 24, characterized in that the containers (102) are pre-flanged carpules (104), wherein a pre-flanged end (110) of the carpule (104) is arranged at the bottom in the carrier (106) and the insertion opening (116) is provided for inserting a plug element (150).

26. System (100) according to one of claims 22 to 25, characterized in that the system (100) comprises a testing station (227) with which the container (102) can be checked to determine whether the fill level corresponds to the target fill level (166).

27. System (100) according to one of claims 22 to 26, characterized in that the system (100) comprises a closing station (148) arranged downstream of the filling station (132) in a processing direction, and in 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 desired position.

28. System (100) according to claim 27 in conjunction with claim 26, characterized in that the container (102) can be checked with the testing station (227) to determine whether the position of the plug element (150) corresponds to the desired position.

29. System (100) according to claim 27 or 28, characterized in that the system (100) comprises a control station (152) downstream of the closing station (148) in a processing direction.

30. Plant (100) according to one of claims 22 to 29, characterized in that at least one processing station comprises a further filling station (122) which is arranged 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 filling level (130) and are filled at the filling station (132) with the filling needle device (136) up to the desired filling level (166).

31. Plant (100) according to claim 30, characterized in that by means of the dosing device (140) it is possible to determine which product quantity of the product is filled in order to fill the containers (102) from the first filling level (130) to the desired filling 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 product quantity or smaller product quantity in order to achieve a higher first filling level (130) or lower first filling level (130).

32. System (100) according to one of claims 22 to 31, characterized in that the system (100) comprises a gas supply device (142) coupled to the control device (128) and in flow connection with the connection element (258) via a supply line (260), wherein the gas supply device (142) is selectively activatable for supplying the filling needle device (136) with gas.

33. System (100) according to claim 32, characterized in 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) are selectively movable relative to one another, and in that the gas supply device (142) can be activated when the filling needle device (136) has a cleaning position relative to the container (102).

34. A 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 21 or a system according to one of claims 22 to 33, comprising: Inserting the filling needle device (136) into the container (102) via an insertion opening (116); as a component of the filling needle device (136) or separately therefrom, inserting at least one electrode (178, 180) into the container (102); activating the dosing device (140); Detecting or determining a measurement signal (218) 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 upon reaching a target fill level (166).

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