Robot-Assisted Filling Needle Transfer Into Aseptic Isolators
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Solution Overview
Problem
Existing methods for transferring filling needles into aseptic isolators are time-consuming, prone to contamination, and do not meet the demands for dosing accuracy and reproducibility, particularly when manual handling is involved.
Innovation Solution
A method and system for robot-assisted transfer of filling needles using a first and second needle carrier, where the needles are held directly by a robot end effector, enabling automated and safe transfer within an aseptic isolator through a transfer lock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling is used to transfer filling needles into the isolator, then the transfer can be performed with simple equipment, but the process becomes time-consuming and prone to contamination
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robot system. The robot end effector mechanically grasps filling needles from a first needle carrier and transfers them to a second needle carrier inside the isolator, eliminating human hands from the sterile environment and thereby reducing contamination risk while maintaining operational simplicity through automation.
Solution Approach 2:
The robot system performs the transfer operation autonomously without requiring manual intervention. The automated gripper picks up needles from the first carrier and places them in the second carrier independently, making the system self-sufficient and eliminating the need for operator involvement in the critical transfer process.
2Manufacturing precision
If manual handling is used for transferring filling needles, then the operation can be performed with simple equipment, but dosing accuracy and reproducibility are compromised
Solution Approach 1:
The patent replaces imprecise manual manipulation with a robot end effector that provides consistent, repeatable grasping and placement actions. The robotic system's precise positioning and controlled movement ensure uniform handling of filling needles, thereby improving dosing accuracy and reproducibility while the automated nature eliminates human variability.
3Reliability
If glove ducts are used for manual intervention, then isolated intervention is possible without contaminating products, but the gloves quickly become damaged when gripping filling elements
Solution Approach 1:
The patent eliminates the use of rubber or plastic glove ducts by employing a robot end effector for handling filling needles. The robotic gripper directly interacts with the needles without requiring protective gloves, thereby removing the durability problem of gloves while maintaining contamination prevention through the sealed isolator environment and automated sterile transfer.
4Productivity
If automated robot transfer is implemented, then efficiency and throughput are improved, but the system complexity increases
Solution Approach 1:
The robot system performs the entire transfer operation autonomously, picking up filling needles from the first needle carrier and placing them in the second carrier without human intervention. This self-service capability enables high-speed automated transfer, improving throughput while the integration of the robot with the isolator system manages complexity through coordinated automation.
Data Source
AI summary
A method for transferring at least one filling needle of a number of filling needles into an isolator which has a transfer lock, the method having the following steps: providing a first needle carrier within the transfer lock, said needle carrier carrying the number of filling needles; providing a second needle carrier in a first position within the isolator; robot-assisted transferring of the at least one filling needle of the number of filling needles from the first needle carrier to the second needle carrier; and robot-assisted placing of the at least one filling needle of the number of filling needles in the second needle carrier, wherein the at least one filling needle of the number of filling needles is held directly during the robot-assisted placing. A transfer system, in which such a method can be conducted, is also disclosed.