Automated Smart Tank Assembly System for Bio-Pharma
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Solution Overview
Problem
Conventional single-use bio-pharma process lines are complex, time-consuming, and costly to set up, prone to malfunctions, and have limited sterilization capacity, leading to drug shortages and economic risks due to the need for frequent replacement and gamma sterilization, which affects plastic components and has limited capacity.
Innovation Solution
An automated assembly system for modular smart tanks that includes a mobile storage means for sterilized components, allowing for assembly under clean room conditions using a manipulator, facilitating efficient assembly, reduced sterilization time, and reusability of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual assembly is used for single-use bio-pharma process lines, then components can be assembled, but the setup time increases to about one day and costs become very expensive
Solution Approach 1:
The patent replaces manual mechanical assembly with an automated assembly system that uses a manipulator robot to assemble smart tank components. This automation eliminates the need for manual pre-assembly operations, reducing setup time from one day to a significantly shorter duration while maintaining assembly quality and precision.
Solution Approach 2:
The patent implements pre-sterilization of individual components before assembly, allowing them to be sterilized separately and then automatically assembled. This preliminary action enables the assembly process to occur under clean room conditions without requiring extensive post-assembly sterilization, thereby reducing overall setup time and costs.
2Reliability
If gamma sterilization is used for single-use bio-pharma process lines, then sterilization is achieved, but plastic components are negatively affected and sterilization capacity is limited
Solution Approach 1:
The patent divides the sterilization process into separate stages where individual components are sterilized before assembly rather than sterilizing the complete assembled system. This segmentation allows for gentler sterilization methods to be applied to plastic components, avoiding the harsh effects of gamma radiation while maintaining sterilization effectiveness.
Solution Approach 2:
The patent changes the sterilization parameters by using alternative methods such as autoclaving or chemical sterilization instead of gamma sterilization for plastic components. This parameter change preserves the integrity of plastic materials while achieving the required sterilization levels, eliminating the harmful effects on component durability.
3Ease of manufacture
If single-use bio-pharma process lines are used, then maintenance and cleaning are simplified, but components cannot be reused and must be discarded after use
Solution Approach 1:
The patent applies the disposable principle to specific consumable components such as seals and gaskets that are inexpensive to replace, while making the main smart tank structure reusable. This selective disposability maintains the simplicity of maintenance while reducing waste of expensive components.
Solution Approach 2:
The patent implements a system where the smart tank components are designed for recovery and reuse after a certain number of cycles, while only the consumable seals and gaskets are discarded. This approach balances the simplicity of single-use systems with the economic benefits of component reuse, reducing overall material waste.
4Productivity
If automated assembly is implemented for smart tanks, then setup time and costs are reduced, but the system complexity increases
Solution Approach 1:
The patent designs the smart tank components with standardized interfaces and universal connection mechanisms that work across different tank configurations. This universality simplifies the automated assembly process by reducing the number of specialized operations needed, thereby increasing assembly speed without proportionally increasing system complexity.
Data Source
AI summary
The present invention relates to an assembly system for assembling a modular smart tank, a method for assembling a modular smart tank, a mobile storage means and an assembly bag. The assembly system comprises at least one mobile storage means for storing components of at least one smart tank, an assembly room, wherein the assembly room is adapted to provide clean room conditions and wherein the assembly room is configured to allow assembly of at least one smart tank within the assembly room from the components stored in the mobile storage means, and a manipulator, being adapted to automatically assemble the smart tank within the assembly room.