Robotic 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 fail to meet the demands for dosing accuracy and reproducibility due to manual handling and the use of glove ports, which can be damaged and pose a risk of leaks.
Innovation Solution
A method and system for robotically transferring filling needles into an aseptic isolator using a needle carrier with a base body and receptacle, where the needles are robotically picked up, transferred, and arranged in a filling position within the isolator, ensuring direct handling by a robot end effector to maintain aseptic conditions and enhance accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling through glove ports is used to transfer filling needles, then ease of operation is maintained, but productivity decreases and contamination risk increases
Solution Approach 1:
The patent replaces manual mechanical handling through glove ports with an automated robotic system. The robot end effector directly grasps and transfers filling needles from the transfer port to the filling station, eliminating the need for manual glove operations and significantly improving productivity while maintaining aseptic conditions.
Solution Approach 2:
The system enables self-service automation where the robotic end effector autonomously performs the transfer operation without human intervention. The robot picks up the needle carrier, transfers it through the transfer port, and positions it at the filling station automatically, making the process independent of manual dexterity or glove manipulation.
2Ease of operation
If manual handling through glove ports is used to transfer filling needles, then ease of operation is maintained, but the risk of contamination increases
Solution Approach 1:
The patent replaces manual mechanical handling through glove ports with an automated robotic system. The robot end effector directly grasps and transfers filling needles from the transfer port to the filling station, eliminating the need for manual glove operations and significantly improving productivity while maintaining aseptic conditions.
Solution Approach 2:
The patent extracts the vulnerable glove port interface from the critical transfer path. By using a robotic end effector that can directly access the transfer port and hold the needle carrier, the system removes the intermediate glove layer that was causing contamination risks, thereby improving reliability while maintaining operational ease.
3Ease of operation
If manual handling of filling needles is used, then ease of operation is maintained, but manufacturing precision decreases
Solution Approach 1:
The patent replaces manual mechanical handling through glove ports with an automated robotic system. The robot end effector directly grasps and transfers filling needles from the transfer port to the filling station, eliminating the need for manual glove operations and significantly improving productivity while maintaining aseptic conditions.
Solution Approach 2:
The system enables self-service automation where the robotic end effector autonomously performs the transfer operation without human intervention. The robot picks up the needle carrier, transfers it through the transfer port, and positions it at the filling station automatically, making the process independent of manual dexterity or glove manipulation.
4Ease of operation
If glove ports are used for transferring filling needles, then ease of operation is maintained, but device complexity increases due to glove maintenance
Solution Approach 1:
The patent extracts the vulnerable glove port interface from the critical transfer path. By using a robotic end effector that can directly access the transfer port and hold the needle carrier, the system removes the intermediate glove layer that was causing contamination risks, thereby improving reliability while maintaining operational ease.
Solution Approach 2:
The patent eliminates the need for disposable gloves by using a reusable robotic end effector system. Instead of continuously replacing and managing glove inventory, the system uses a durable robotic gripper that can be sterilized and reused, reducing device complexity and maintenance requirements while maintaining operational ease.
Data Source
Figure 1~2
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Figure 5A~5B
AI summary
The present invention relates to a method (100) for transferring at least one filling needle (20) of a number of filling needles (18) into an isolator (12) having a transfer lock (14), wherein the method (100) comprises the following steps: providing (102) a first needle carrier (16) inside the transfer lock (14) carrying the number of filling needles (18); providing (104) a second needle carrier (22) in a first position (24) inside the isolator (12); robotically transferring (106) the at least one filling needle (20) of the number of filling needles (18) from the first needle carrier (16) to the second needle carrier (22); and robot-assisted arrangement (108) of the at least one filling needle (20) of the number of filling needles (18) in the second needle carrier (22), wherein the at least one filling needle (20) of the number of filling needles (18) is held directly during the robot-assisted arrangement (108).Furthermore, the present invention relates to a transfer system (10) in which such a method (100) can be carried out.