Robotic Manipulator for Sterile Component Transfer
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Solution Overview
Problem
In pharmaceutical and biotechnological industries, manual handling of sterile equipment and components in cleanrooms poses risks of contamination and health hazards due to direct operator contact, requiring costly and time-consuming sterilization procedures and frequent operator turnover.
Innovation Solution
An apparatus for transferring and moving elements associated with operating machines, such as packaging machines, that allows for automatic assembly and dismantling without direct manual intervention, maintaining sterility and preventing operator exposure to hazardous materials, using a trolley with moving arrangements and gripping mechanisms to handle and transfer components within a controlled atmosphere.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling of sterile equipment and components is performed by operators in cleanrooms, then assembly and dismantling operations can be performed with simple equipment, but contamination risks increase and health hazards arise due to direct operator contact
Solution Approach 1:
The patent introduces a robotic manipulator system as an intermediary between operators and sterile components. The manipulator performs all assembly and dismantling operations within the cleanroom environment, eliminating direct contact between operators and sterile equipment. The system includes a robotic arm with grippers that can precisely handle components, and a control station that allows operators to remotely operate the manipulator without entering the sterile zone.
Solution Approach 2:
The system divides the workspace into two distinct zones: a sterile zone containing the cleanroom and equipment, and a non-sterile zone containing the operator control station. The robotic manipulator acts as a bridge between these zones, allowing material and information flow while maintaining physical separation. This segmentation enables operators to control the system from outside the sterile environment while the manipulator performs tasks inside.
2Reliability
If manual sterilization procedures are performed frequently to maintain sterility, then contamination risks are reduced, but operational time and costs increase
Solution Approach 1:
The robotic manipulator system is designed to maintain sterility through self-service mechanisms. The manipulator and its end effectors are constructed from sterilizable materials and can be sterilized in place using autoclave or other appropriate methods. The system includes sealed compartments and sterilizable tooling that can be sterilized between batches without requiring full facility shutdown or extensive re-sterilization procedures.
Solution Approach 2:
The system performs preliminary sterilization of components and the manipulator itself before entering the cleanroom environment. All components are pre-sterilized and stored in sterile containers until needed. The manipulator undergoes sterilization cycles between production runs, and the system is designed to minimize the frequency and duration of sterilization operations through efficient workflow planning and rapid sterilization capabilities.
3Adaptability or versatility
If operators frequently enter and exit the cleanroom to perform interventions, then operational flexibility is maintained, but sterility is compromised and restoration procedures are required
Solution Approach 1:
The robotic manipulator serves as an intermediary that performs all interventions within the cleanroom without requiring operator entry. The manipulator can be repositioned, reconfigured, and operated to perform various assembly and dismantling tasks while maintaining the sterile barrier. Operators interact with the system through a control interface located outside the cleanroom, allowing flexible operation without compromising sterility.
Solution Approach 2:
The system provides dynamic adaptability through programmable robotic movements and interchangeable end effectors. The manipulator can be programmed to perform different sequences of operations, and tooling can be changed to match specific task requirements. This dynamic capability maintains operational flexibility while eliminating the need for operators to physically enter the sterile environment to adapt or intervene in the process.
4Object-affected harmful factors
If automated moving arrangements are introduced to transfer components, then operator exposure to hazardous materials is minimized, but device complexity increases
Solution Approach 1:
The robotic manipulator system acts as an intermediary transport mechanism that handles all component transfer operations within and into the cleanroom. The system includes automated feeding mechanisms, robotic grippers, and controlled movement systems that eliminate direct operator contact with components. While the system is complex, it is contained within a dedicated workstation that can be integrated into existing production lines.
Solution Approach 2:
The patent replaces manual mechanical handling with automated robotic manipulation. The system uses computer-controlled motors, sensors, and programmable logic to perform tasks that would otherwise require manual dexterity and contact. This substitution reduces operator exposure to hazardous materials while automating the complex tasks of component manipulation, positioning, and assembly within the sterile environment.
Data Source
AI summary
An apparatus for transferring and moving elements that are removably associable with an operating machine comprises a moving arrangement suitable for receiving and supporting the elements, the moving arrangement being movable for transferring to and/or removing from the operating machine the elements; the operating machine comprises a supporting arrangement configured for receiving from and giving to the apparatus the elements, the supporting arrangement in turn comprising hooking elements suitable for abutting and locking abutting elements of the elements.