Modular Medical Bag Manufacturing System with Lateral Feed Lines
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Solution Overview
Problem
Existing systems for manufacturing medical bags, particularly ostomy bags, lack flexibility and efficiency in handling and processing multiple layers of film and nonwoven materials, leading to limitations in product variability and quality.
Innovation Solution
A system with a semi-finished product transport system featuring a main line and laterally arranged feed lines, equipped with grippers and tools that allow for automatic feeding, pre-processing, and welding, enabling easy product changes and maintaining consistent working height across all lines, which enhances the handling and processing of multiple layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If film layers are guided in separate planes and brought into one plane for welding, then welding can be performed, but the system complexity increases and handling becomes more difficult
Solution Approach 1:
The patent guides film layers in separate planes (different vertical dimensions) through the feeding process, then brings them into one plane at the welding station. This dimensional approach allows multiple layers to be handled independently until needed, reducing interference during processing while enabling precise welding when required.
Solution Approach 2:
The system separates the handling of multiple film layers into independent feeding lines, each processing one layer at a time in separate planes. This segmentation allows each layer to be processed independently with appropriate tools, reducing overall system complexity while maintaining welding precision through controlled convergence at the welding station.
2Adaptability or versatility
If manual handling and processing of semi-finished products is used, then flexibility in processing is maintained, but productivity decreases
Solution Approach 1:
The system employs automatic feeding mechanisms where semi-finished products feed themselves from the feeding lines into the processing position through self-aligning features and gravity-assisted movement. This reduces manual handling while maintaining processing flexibility through programmable tool operations and adjustable feeding rates.
Solution Approach 2:
Semi-finished products are pre-positioned and pre-oriented on the feeding lines before reaching the processing station. This preliminary action includes pre-alignment of layers and pre-positioning of components, which maintains flexibility for different product configurations while increasing productivity by eliminating manual setup at each processing cycle.
3Adaptability or versatility
If product changes are implemented frequently, then product variability increases, but production time is lost during changes
Solution Approach 1:
The system incorporates dynamically adjustable components including variable feeding rates, adjustable tool positions, and reconfigurable feeding line configurations. These dynamic features allow rapid adaptation to different product specifications without requiring complete system reconfiguration, reducing changeover time while maintaining high product variability.
Solution Approach 2:
The feeding lines and processing tools are designed with universal capabilities to handle multiple product types and configurations. Standardized interfaces and modular components allow the same system to process different semi-finished products by adjusting parameters rather than changing physical infrastructure, enabling frequent product changes without production time loss.
4Ease of operation
If multiple feeding lines are arranged laterally, then access to main line is improved, but space requirements increase
Solution Approach 1:
The feeding lines are arranged laterally in a compact configuration where components are nested or closely integrated along the main line. This nesting approach allows multiple feeding lines to access the main processing line without requiring excessive lateral space, improving accessibility while minimizing the overall footprint of the manufacturing system.
Data Source
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AI summary
The invention relates to a system for manufacturing a medical device, primarily in the form of an ostomy bag, and a method for operating such a system. Conventional systems use various film lines at different levels and intervals, thus enabling preliminary processing steps. The films are then brought together in one level and welded together. The present invention presents a highly flexible, modular system concept in which individual feed lines for semi-finished products are provided. The feed lines can transfer pre-assembled semi-finished products to a main line. In the main line, the final processing of the semi-finished products into the finished product or into another semi-finished product takes place with the highest possible precision.