Modular Syringe Carriage Assembly for Rapid Size Changeovers
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Solution Overview
Problem
Existing automated machines for coupling plunger rods to medicinal syringe assemblies are cumbersome, requiring skilled operators and extensive time for changeovers between different sizes, and are impractical for small batches due to their large size and complexity.
Innovation Solution
A machine with interchangeable carriages and an adaptive actuating system that allows for quick changeovers between different syringe assembly sizes, featuring a movable cradle and actuating device to efficiently couple plunger rods to syringe assemblies, reducing the need for extensive retooling and minimizing operator error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fully automated machine is used for coupling plunger rods to syringe assemblies, then productivity is improved for large batches, but device complexity and footprint increase, making it impractical for small batches and different sizes
Solution Approach 1:
The machine is divided into modular components: a base unit and interchangeable carriages. Each carriage is designed to handle specific syringe assembly sizes, allowing the system to be segmented into functional modules that can be independently selected and swapped based on production needs.
Solution Approach 2:
The system transitions from a static, fixed-configuration automated machine to a dynamic, reconfigurable system. Carriages can be quickly interchanged on the base unit, enabling the machine to adapt its capacity and configuration dynamically based on batch size and syringe dimensions, thereby maintaining productivity across varying production scenarios.
2Productivity
If a fully automated machine is used for coupling plunger rods to syringe assemblies, then productivity is improved for large batches, but the changeover process requires skilled operators and extensive time
Solution Approach 1:
Different carriages are pre-configured for specific syringe assembly sizes and capacities. Before a production run, the appropriate carriage is selected and pre-installed on the base unit, eliminating the need for complex adjustments and retooling during changeovers. This preliminary preparation significantly reduces changeover time and minimizes the skill level required for operator intervention.
Solution Approach 2:
The system enables rapid parameter changes by physically swapping carriages with different capacity specifications. Each carriage is designed with standardized interfaces that allow quick attachment and detachment, facilitating immediate parameter adjustment (syringe size, batch capacity) without time-consuming reconfiguration procedures.
3Productivity
If a fully automated machine is used for coupling plunger rods to syringe assemblies, then productivity is improved, but the machine has a large footprint and is non-portable
Solution Approach 1:
The machine footprint is reduced by segmenting the system into a compact base unit and separate carriages. The base unit contains only the essential actuating mechanisms and carriage interface, minimizing the stationary footprint. Carriages can be stored separately or stacked, further reducing the space required when not in use.
Solution Approach 2:
A single base unit serves multiple functions by accommodating different carriages for various syringe assembly sizes. This multi-functionality eliminates the need for multiple dedicated machines for different product lines, consolidating capabilities into one compact platform that maintains high productivity across diverse applications.
4Productivity
If existing automated machines are used, then large batches can be assembled efficiently, but they are impractical for small batches and syringe assemblies of different sizes
Solution Approach 1:
The system achieves dynamic adaptability through interchangeable carriages that can be selected based on the specific syringe assembly size and batch requirements. Each carriage is optimized for particular capacity ranges, allowing the machine to dynamically adjust its configuration to match production needs, whether for small batches with varied sizes or large batches with consistent dimensions.
Solution Approach 2:
The system facilitates parameter changes by providing a range of carriages with different capacity specifications. Operators can select the appropriate carriage based on the syringe assembly size and batch volume required, enabling the machine to adapt its operational parameters (capacity, speed, configuration) to optimize productivity for both small and large batches across different product lines.
Data Source
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AI summary
A machine for coupling a plunger rod to a syringe assembly may include a carriage including a cradle having a seat portion sized to receive a syringe assembly and an aperture portion disposed above the seat portion and sized to receive a plunger rod. An actuating device may be operatively coupled to the carriage and adapted to move the cradle from a first position to a second position to couple the plunger rod to the syringe assembly. The carriage may be selected from separate and interchangeable first and second carriages, wherein the first carriage includes a cradle adapted to receive a syringe assembly of a first size and the second carriage including a cradle sized to receive a syringe assembly of a second size that is different from the first size.