Lyophilizer Loader Robotics for Parallel Aseptic Nest Transfer
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Solution Overview
Problem
Existing pharmaceutical container loading systems for lyophilization are serial in nature, leading to potential process halts due to entrainment errors and reduced throughput.
Innovation Solution
An integrated pharmaceutical processing system utilizing a multi-nest support mechanism and an articulated robotic arm to transfer multiple container nests in parallel, enabling simultaneous loading into a lyophilizer while maintaining aseptic conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential loading of pharmaceutical containers is used, then device complexity is reduced, but productivity is decreased
Solution Approach 1:
The loading system is segmented into multiple independent nest handlers, each capable of loading a nest of containers independently. This allows parallel loading operations while keeping each individual handler relatively simple in design, thus improving overall productivity without excessive complexity increase.
Solution Approach 2:
Multiple nest support mechanisms are merged into a single integrated loading system that operates in coordination. The system combines multiple loading capabilities while sharing common control and infrastructure, achieving high throughput without proportionally increasing overall system complexity.
2Reliability
If sequential loading is used, then ease of operation is improved, but reliability is worsened
Solution Approach 1:
Multiple nests are prepared and staged in advance before loading begins. The system performs preliminary positioning and verification of multiple nests, ensuring that loading can continue without interruption if one nest encounters an issue, thus improving reliability while maintaining operational simplicity.
Solution Approach 2:
Each nest handler is designed with localized error handling and verification capabilities. If one nest or handler encounters a problem, the local quality control features detect and isolate the issue without affecting other handlers, ensuring process continuity while keeping each unit simple to operate.
3Productivity
If parallel transfer of multiple nests is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The parallel loading capability is achieved by segmenting the system into multiple identical or similar nest handlers rather than creating one complex unified mechanism. Each handler is relatively simple, but their coordinated operation delivers high productivity through parallelism.
4Productivity
If multiple nest support mechanisms are used, then productivity is improved, but ease of operation is worsened
Solution Approach 1:
Multiple nest support mechanisms are designed with universal interfaces and standardized operations. Each mechanism can handle different nest types and configurations, allowing a single operator to control all handlers using the same procedures, thus maintaining ease of operation while achieving high batch loading capacity.
Data Source
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AI summary
Abstract: Disclosed are systems and methods for aseptically filling pharmaceutical containers with a pharmaceutical substance and then lyophilizing it. In one general aspect, the system and method can employ a lyophilizer loader subsystem having an interior chamber in communication with an interior chamber of a lyophilizer subsystem via a portal with a sealable door, with the collective interior being aseptically sealable. An articulated robotic arm can be employed to batch transfer to the lyophilizer subsystem container nests bearing the pharmaceutical containers. In one embodiment, the nests may be transferred serially to the loader subsystem, with the articulated robotic arm being configured to transfer the nests of containers in batches to the lyophilizer subsystem. The articulated robotic arm can also be configured to be used to move batches of nests within the lyophilizer subsystem. One implementation includes two articulated arms and a joint rotary wrist driven by two rotary shoulders.