Robotic Sterile Bagging for Precise Pharmaceutical Container Packaging
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Solution Overview
Problem
Existing packaging apparatuses for pharmaceutical containers, such as syringes, face challenges in ensuring accurate and repeatable positioning of protective sheets for hermetic sealing, maintaining sterility under ISO5 conditions, and controlling air inside bags, leading to inefficiencies and waste.
Innovation Solution
A robotic packaging apparatus equipped with a robotic closing arm, position control cameras, centring pins, suction cups, and a laminar air flow system for precise sheet positioning and welding, along with a robotic bagging arm and integrity control cameras for accurate bag handling and air evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning methods are used for protective sheets, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated system comprising a robotic arm, position control camera, and feedback control mechanism. The camera captures the position of the protective sheet and container, the control unit processes this information, and the robotic arm adjusts positioning automatically, achieving high precision without manual intervention.
Solution Approach 2:
The patent implements a feedback control system where the position control camera continuously monitors the position of the protective sheet relative to the container, feeds this information to the control unit, which then commands the robotic arm to make real-time adjustments. This closed-loop feedback ensures positioning precision while automating the process.
2Manufacturing precision
If automated positioning systems are implemented, then manufacturing precision improves, but productivity deteriorates
Solution Approach 1:
The patent performs preliminary positioning actions by using the position control camera to capture and analyze the positions of the protective sheet and container before the actual welding operation. The control unit calculates the required adjustments in advance, and the robotic arm executes these pre-computed positioning movements, ensuring both precision and speed without delays during the welding process.
3Ease of operation
If protective sheets slide during handling, then ease of operation improves, but reliability deteriorates
Solution Approach 1:
The patent replaces manual handling of protective sheets with an automated robotic arm system that uses suction cups or clamps to grip and transport the sheets. This automated mechanical system provides controlled, slide-free handling while maintaining ease of operation through programmable movements, ensuring reliability and sterility assurance.
Solution Approach 2:
The patent introduces an intermediary positioning platform or vacuum holding surface between the protective sheet and the robotic arm. This intermediary surface prevents sliding by providing friction or vacuum adhesion during transfer, while the robotic arm maintains ease of operation through automated control. The position control camera monitors the entire process to ensure reliability.
4Object-affected harmful factors
If air is not evacuated from bags, then device complexity is reduced, but harmful factors increase
Solution Approach 1:
The patent extracts air from the packaging bag using a vacuum system or compression device that removes air through a valve or port in the bag. This extraction process eliminates the harmful air pressure effect that could cause bag rupture, while the system complexity is managed through automated integration with the packaging process control.
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
The apparatus ensures precise and repeatable positioning of protective sheets, maintains sterility, reduces waste, and automatically checks weld integrity, while evacuating air from bags to prevent over-inflation and breakage, enhancing the efficiency and reliability of the packaging process.
Implementation Method 1
said robotic closing arm being connected to at least one position control camera configured to acquire coordinates of a centre of gravity of said outer protective sheet with respect to a lying plane on which said outer protective sheet lies and/or an angle of rotation of said outer protective sheet with respect to an axis perpendicular to said lying plane, so as to ensure correct positioning and release of said outer protective sheet at said perimeter edge
Implementation Method 2
The sealing of the container by welding the outer protective sheet, upon correctly positioning of the outer protective sheet on the open container, takes place by a hot bar that is pressed on top by the system with a controlled force and time
Implementation Method 3
a laminar air flow is applied throughout all the packaging steps in order to ensure sterility and to prevent contaminating particles from entering the container to be sealed
Implementation Method 4
said robotic bagging arm being connected to at least one position control camera configured to acquire coordinates of a midpoint of said opening with respect to a lying plane on which said bag lies (prior to its opening) and/or an angle of rotation of said bag with respect to an axis perpendicular to said lying plane, so as to ensure correct positioning and release of said container inside said bag
Implementation Method 5
the sealing of the bag (steribag) is performed by a welding bar that is pressed onto the bag by the system with a controlled force and time
Implementation Method 6
The apparatus comprises a suction device configured to evacuate air from inside said bag
Data Source
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AI summary
Apparatus (4) for the packaging of containers (8) of devices for pharmaceutical use, comprising: - a robotic arm (112) movable from a gripping position, in which it picks up a container (8) previously sealed by at least one protective sheet, to a release position in which it inserts said container (8) into a bag through a suitable opening provided on a side of the bag; - wherein said robotic arm (112) is connected to at least one position control camera (78) configured to read coordinates of a midpoint of said opening with respect to a lying plane on which said bag lies and/or an angle of rotation of the bag with respect to an axis perpendicular to said lying plane, so as to ensure the correct positioning and release of the container (8) inside the bag.