Multi-track Syringe Filling with Parallel Weighing
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Solution Overview
Problem
Current methods for filling medical containers, such as syringes, are inefficient due to the need for precise weighing before and after filling, which slows down the process and increases costs, while also being labor-intensive and prone to deviations in filling quantities.
Innovation Solution
A system with multiple tracks for transporting and filling containers, featuring at least two weighing devices and a control mechanism that allows rows of containers to pass by one weighing device while stopping at another for filling, enabling simultaneous weighing of two rows at each filling stop, thus speeding up the process and ensuring precise filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If every individual container is weighed before and after filling to ensure precise filling quantity, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The system divides the weighing and filling process into separate functional modules: tare weighing station, filling station, and gross weighing station. Multiple weighing devices are arranged in parallel to handle different rows simultaneously, segmenting the workload to maintain precision while improving throughput
Solution Approach 2:
The system transitions from sequential single-row processing to parallel multi-row processing by arranging weighing devices and filling stations in multiple tracks. Rows are processed simultaneously in different spatial dimensions, dramatically increasing productivity while each row still receives individual weighing attention
2Manufacturing precision
If manual filling is used to ensure precise control, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
Manual filling operations are replaced with automated filling machines equipped with precise dosing mechanisms. The system uses computer-controlled filling needles and metering pumps to deliver exact volumes, maintaining the precision of manual operations while achieving industrial-scale throughput
Solution Approach 2:
The system incorporates weight feedback from weighing devices to control the filling process. Weight measurements are fed back to the control system, which adjusts filling parameters in real-time to ensure each container receives the precise target quantity, automatically compensating for variations
3Reliability
If multiple weighing operations are performed on each row to verify filling quantity, then reliability is improved, but loss of time increases
Solution Approach 1:
The system merges the tare weighing and gross weighing operations into a streamlined sequential process. Containers are weighed empty, filled, then weighed again in a continuous flow through multiple stations, eliminating redundant handling and transport time while maintaining verification reliability
Solution Approach 2:
Tare weighing is performed in advance before filling operations begin. This preliminary measurement allows the control system to pre-calculate target gross weights and prepare filling parameters, reducing waiting time during the actual filling and verification process
Data Source
AI summary
A system for filling containers, in particular syringes, comprising a multi-track transport device for transporting a plurality of rows of containers in a transport direction; at least two weighing devices, which are arranged in succession in the transport direction; at least one multi-track filling station, wherein the number of tracks of the filling station matches the number of tracks of the transport device; at least one sealing station; means for placing each row of containers on one of the at least two weighing devices; and control configured to actuate the transport device such that each row of containers is placed at a relevant weighing device for a filling process, wherein the row of containers merely passes by the other weighing devices without being placed at these other weighing devices for a filling process.