Needle Shield Positioning System for Syringe Assembly
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Solution Overview
Problem
Existing methods for mounting needle shields onto syringes are inconsistent and labor-intensive, leading to rejections due to misorientation and contamination risks, especially in assembly line environments.
Innovation Solution
A system comprising a syringe nest, gripper, shaker, cap plunger, and inspection camera is used to align and secure needle shields onto syringes, employing a pick-and-place mechanism with vibration to ensure proper orientation and positioning, followed by verification and final engagement to prevent misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hand application processes are used to assemble needle shields to syringes, then labor intensity is reduced, but consistency and reliability of mounting deteriorate
Solution Approach 1:
The patent replaces manual hand application processes with an automated mechanical assembly system. The system uses a robotic arm to pick needle shields from a storage magazine and place them onto syringes in a controlled manner, eliminating the variability and labor intensity of manual assembly while ensuring consistent and reliable mounting through precise mechanical control.
2Productivity
If automated pick and place methods are used to mount needle shields, then productivity increases, but misorientation rejections increase
Solution Approach 1:
The patent incorporates an optical inspection system that uses cameras and image processing to verify the orientation of needle shields after they are placed on syringes. The system captures images, processes them to determine orientation, and provides feedback to the robotic arm to correct misorientations or reject improperly assembled units, thereby maintaining high productivity while ensuring orientation accuracy.
Solution Approach 2:
The patent employs ultrasonic vibration during the assembly process to facilitate proper seating and orientation of the needle shield on the syringe. The vibration helps the needle shield settle into the correct position and orientation, reducing misorientation rejections while maintaining high assembly speed through automated pick and place operations.
3Productivity
If increased pressure is applied during needle shield assembly, then mounting speed increases, but needle exposure risk increases
Solution Approach 1:
The patent positions the needle shield and syringe in precise predetermined locations using the robotic arm before assembly occurs. The system pre-aligns the components and controls the assembly pressure through programmed mechanical motion, ensuring that the needle shield is properly seated without excessive force that could cause needle exposure, while maintaining assembly speed through automated sequencing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system significantly reduces rejections and ensures reliable mounting of needle shields, enhancing safety by preventing contamination and ensuring proper sealing of syringes during shipping.
Implementation Method 1
moving a distal end of the shaker into engagement with the syringe nest and causing the shaker to vibrate the syringe nest to orient a syringe axis generally coaxially with a shield axis of the needle shield
Implementation Method 2
moving the gripper from the gripping position to a released position, thereby causing the needle shield to fall under the force of gravity toward the tip such that the needle shield is positioned on the tip end of the syringe
Data Source
AI summary
A system for mounting a needle shield to a syringe. The system includes a syringe nest and a gripper having a gripping position and a release position. The gripper is movable between an aligned position and a spaced position. A shaker has a shaker axis that is generally coaxial with the syringe axis. The shaker is movable along the shaker axis. An inspection camera is positioned proximate the syringe axis and defines a line of sight. The syringe nest, gripper, shaker and cap plunger are generally aligned along the syringe axis in a placing configuration wherein the gripper is in the gripping position holding the needle shield. The gripper is in the spaced position and the distal end of the cap plunger is in engagement with the needle shield in a final cap mounting configuration.