Filling Needle Transfer Lock for Aseptic Robotic Handling
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Solution Overview
Problem
Existing methods for transferring filling needles into aseptic isolators are time-consuming, prone to contamination, and lack dosing accuracy and reproducibility, particularly when manual handling is involved, and existing robotic systems either require pre-arrangement of syringes or omit the transfer process entirely.
Innovation Solution
A method and system for robot-assisted transfer of filling needles using needle carriers within a transfer lock, involving a first needle carrier outside the isolator and a second within it, with direct handling by a robot end effector for precise and automated transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling through glove ducts is used to transfer filling needles into the isolator, then the isolator remains sealed and contamination is prevented, but the process becomes extremely time-consuming and labor-intensive
Solution Approach 1:
A transfer lock is introduced as an intermediary device between the clean room and the isolator. The transfer lock receives filling needles through a first opening and transfers them to a second opening, enabling automated robotic handling while maintaining the sealed environment of the isolator. This mediator allows robotic arms to operate without compromising the sterile barrier.
2Productivity
If robotic systems are used to transfer filling needles, then productivity and dosing accuracy improve, but the system complexity increases
Solution Approach 1:
The transfer system is segmented into distinct functional zones: a clean room area for preparing filling needles, a transfer lock chamber for automated transfer, and the isolator for filling operations. Each zone has specific openings (first opening for needle entry, second opening for robotic transfer) that divide the complex process into manageable segments, reducing overall system complexity while maintaining high productivity.
3Ease of operation
If filling needles are pre-arranged in carriers outside the isolator, then the transfer process is simplified, but flexibility in handling different needle arrangements is reduced
Solution Approach 1:
The robot end effector is designed with dynamic gripping capabilities that can adapt to different needle arrangements and carrier configurations. Rather than requiring pre-arranged needles in fixed patterns, the robotic system can dynamically adjust its gripping mechanism to handle various needle configurations, maintaining both simplicity in transfer and flexibility in adaptation.
Data Source
AI summary
A method for transferring at least one filling needle of a number of filling needles into an isolator which has a transfer lock, the method having the following steps: providing a first needle carrier within the transfer lock, said needle carrier carrying the number of filling needles; providing a second needle carrier in a first position within the isolator; robot-assisted transferring of the at least one filling needle of the number of filling needles from the first needle carrier to the second needle carrier; and robot-assisted placing of the at least one filling needle of the number of filling needles in the second needle carrier, wherein the at least one filling needle of the number of filling needles is held directly during the robot-assisted placing. A transfer system, in which such a method can be conducted, is also disclosed.