Vial Array Capping System Using Cam-Actuated Gripper Arms
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Solution Overview
Problem
Current methods for capping and de-capping arrays of vials are inefficient, as they require new caps or idle equipment, and do not maintain cap positionality, leading to cross-contamination and high costs.
Innovation Solution
An automated system with a removable cartridge featuring gripper plates and cam-operated gripper arms that simultaneously cap or de-cap vials, allowing for the reuse of original caps and maintaining their positionality, enabling continuous processing of multiple trays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated capping/de-capping tools are used to process vials in arrays, then productivity is improved, but new caps must be used for re-capping or the tool must sit idle, increasing cost and loss of time
Solution Approach 1:
The system separates the capping and de-capping operations into distinct functional modules within the automated tool. The capping module contains cap storage and application mechanisms, while the de-capping module contains cap removal and storage mechanisms. This segmentation allows each module to operate independently and simultaneously, eliminating idle time between operations.
Solution Approach 2:
The system merges the capping and de-capping functions into a single integrated automated tool. Both operations occur within the same device, allowing caps to be removed from one array while caps are stored and ready for re-application to another array, maximizing continuous operation and eliminating tool idle time.
2Loss of substance
If caps are removed and reused after analysis, then cost is reduced, but cross-contamination may occur if cap positionality is not maintained
Solution Approach 1:
The system introduces an intermediary cap storage module that acts as a controlled transition zone between removal and re-application. Caps are transferred through a sealed, tracked pathway with positive identification systems that verify cap-vial matching. This intermediary structure eliminates direct exposure and maintains positional integrity, preventing cross-contamination while enabling cap reuse.
Solution Approach 2:
The system implements feedback mechanisms including bar code scanners, RFID readers, or other identification systems that track each cap's origin and destination. The control system verifies that each cap is returned to its correct vial position before re-capping, providing real-time confirmation that positional integrity is maintained and cross-contamination is prevented.
3Reliability
If multiple trays are processed sequentially, then cross-contamination is prevented, but productivity decreases due to tool idle time
Solution Approach 1:
The system enables continuous operation by allowing multiple trays to be in different stages of processing simultaneously. While one tray is being de-capped, another tray can be positioned for capping, and a third tray can be prepared. The automated tool maintains continuous motion and operation without idle periods, processing multiple trays in parallel streams while maintaining contamination prevention through sealed transfer mechanisms and positive tracking.
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 system ensures efficient, cost-effective capping and de-capping of vials while preventing cross-contamination by retaining original caps in their exact positions, allowing for continuous processing and easy re-capping, reducing waste and operational costs.
Implementation Method 1
The relative positioning of the gripper arms is varied by one or more cams which cause the gripper arms on one or two plates of each set to move relative to the gripper arms of another plate of the set
Data Source
Figure 1a~1b
Figure 2~4d
Figure 5a~5h
AI summary
The system for removing or replacing caps for vials in a fixed array includes a removable cartridge with a plurality of sets of gripper plates corresponding to the number of columns in the array. Each plate has a plurality of gripper arms corresponding to the number of rows in the array. The gripper arms have hooked ends which are oriented in opposite directions in each set of plates. Relative positioning of the gripper arms is varied by one or more rotating cams, which cause the gripper arms on one plate of each set to move relative to the gripper arms of the other plate(s) of the set, varying the combined width and/or relative angle of the gripper arms to manipulate a cap inserted into the end of each vial. The plurality of plate sets and gripper arms allow all vials in the array to be capped or de-capped simultaneously.