Syringe Filling Vacuum Parameter Prediction for Target Plunger Depth
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Solution Overview
Problem
Conventional syringe filling systems require extensive recalibration and guesswork to achieve optimal plunger depth, lacking insight into vacuum setting transferability during changes in syringe filling processes, leading to inefficiencies and resource waste.
Innovation Solution
A method that applies plunger depth and product parameters as inputs to a model to determine vacuum parameters, using experimentally-determined correction factors to characterize the syringe filling system, providing insights for consistent plunger depth achievement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional guess and check methodology is used for vacuum parameter adjustment, then plunger depth specification compliance is achieved, but calibration time and operational complexity increase significantly
Solution Approach 1:
The patent performs preliminary characterization of the syringe filling system by determining correction factors based on experimentally relating plunger depth, vacuum pressure, and product fill amount. This preliminary action creates a predictive model that eliminates the need for time-consuming guess and check calibration procedures during actual operation.
Solution Approach 2:
The patent implements feedback through the use of correction factors that are experimentally determined and stored in the system. These correction factors provide feedback about the relationship between vacuum pressure, plunger depth, and product fill amount, allowing the system to automatically adjust vacuum parameters without manual calibration.
2Manufacturing precision
If extensive recalibration is performed when process changes occur, then plunger depth accuracy is maintained, but productivity and resource efficiency deteriorate
Solution Approach 1:
The patent addresses parameter changes by using a predictive model with correction factors that can be adjusted when process conditions change. Instead of performing extensive recalibration, the system can quickly update correction factors based on the new conditions, maintaining plunger depth accuracy while minimizing disruption to production throughput.
3Manufacturing precision
If manual vacuum parameter adjustment is used, then plunger depth control is achieved, but device complexity and operational difficulty increase
Solution Approach 1:
The patent implements self-service by enabling the syringe filling system to automatically determine and apply vacuum parameters using the predictive model and correction factors. This eliminates the need for manual calibration procedures, reducing device complexity and operational difficulty while maintaining precise plunger depth 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
Reduces resource waste and calibration time, enhances production throughput, and improves sustainability by offering transferable vacuum settings for syringe filling systems.
Implementation Method 1
The plunger depth when filling a syringe is affected by a pressure difference between (1) inside the syringe between the bottom of the plunger and the top of the product, and (2) the space outside the syringe
Data Source
AI summary
Systems and methods for characterizing a recipe of a syringe filling system can include (a) receiving a value of a plunger depth for a syringe, (b) receiving values of product parameters, (c) determining, by applying the value of the plunger depth and the values of the product parameters as inputs to a model, values of vacuum parameters of the syringe filling system for use when filling the syringe with a product having the values of the product parameters, and (d) displaying or storing the values of the vacuum parameters. Further aspects include characterizing a recipe of the syringe filling system for use with a second value of the plunger depth for a second syringe. Still further aspects include causing one or more vacuum devices of the syringe filling system to operate at the values of the vacuum parameters.