Originally Published EMDM
May/June 2003
Equipment News
Recent developments in automation equipment |
Assembly platforms are configured to customer specifications
Custom automated assembly lines are designed and manufactured for the medical device, electronics, and semiconductor industries. Headquartered in La Chaux-de-Fonds, Switzerland, Ismeca Europe Automation S.A. offers turnkey solutions for complex production processes. Production flexibility and the availability of modular plug-and-play configurations are among the most popular features of the automated systems.
Four basic platforms are offered: a synchronous rotary transfer system, an asynchronous pallet transfer system, a synchronous transfer system, and a flexible modular system particularly suited for device manufacturing. Typically, the firm will design a flexible assembly line based on a combination of its assembly platforms that have been adapted to meet client specifications. Systems compatible with FDA validation and cleanroom production environments are a specialty.
Manufacturer expands line of handling and conveying systems
A machine manufacturer serving the medical industry has extended its range of products. AAE B.V. (Helmond, Netherlands) recently introduced its high-speed dual handler (HSDH) and linear conveying system (LCS).
The HSDH is a reliable pick-and-place unit that guarantees precise operation even after a million nonstop movements. A low moving mass results in fast movements and rapid cycle times. The pick-and-place process is achieved by one rotating electrical movement and two separately controlled linear vertical pneumatic strokes. The unit can accommodate various grippers and is available in several heights and widths.
The LCS is based on sturdy alloy chain links with a 125-mm pitch. The fourfold bearing-supported chains are retained in a ground-steel guide with steel sprocket rings; an alloy centre frame has universal mounting slots on which various tools can be mounted. The LCS can be used with indexing systems as well as continuous-motion machines.
Internet project aims to help manufacturers develop assembly and testing systems
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A supplier of automated assembly, testing, and robotic handling equipment, TQC (Nottingham, UK) has been involved in a number of unique automation projects for the pharmaceutical and medical device sectors. “We have conducted various multimillion-dollar integrated projects for handling and packaging of drugs or materials,” says sales and marketing director Mark Jones. “We have also recently improved a sterilization facility in New York, and we are currently developing robotic handling equipment for radioactive drugs.”
One challenge that many manufacturers face at the planning stage, according to Jones, is accurately defining the scope of their assembly and test systems. To help industry with this process, TQC has signed on as manager of a Eureka project with UK partners GSK, Bespak, University of Nottingham, BARA, System Devices, and B4. The E-Race project, as it is called, intends to use the Web to create an automated system that will capture, collate, and process the data needed to define such projects and to estimate the costs involved. “We’re using Internet simulation software to help us design a virtual model of a production facility,” says Jones. Interactive Internet technology “will enable users to evaluate the impact and cost of different assembly methods, product variations, and production volumes.”
Project members also hope to offer a view of the assembly coming together using real-time motion. The model will be constructed with transport conveyors, assembly modules, and robots pulled from a database of proven-technology subassemblies and components.
Although it is in its early stages, the project has already shown that a useful tool for pharmaceutical and medical device manufacturers will be possible. The final results of the project and a usable Web site are expected to be made public by 2006.
Eureka is a Europe-wide government-funded initiative designed to increase competitiveness in new technology. It promotes collaboration between companies, universities, and research institutions across Europe.
Custom assembly systems are designed for medical use
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Cost-effective assembly and test systems are available to medical device manufacturers.
AB Precision (Poole) Ltd. (Poole, Dorset, UK) manufactures systems for contact lens production, diagnostic test kit assembly, metered-dose-inhaler testing, and test-strip production, among others. The machines range from high-volume, high-speed, linear and rotary transfer systems and robot-based cells to individual operator-attended workstations.
The equipment is custom designed and built at the firm’s UK base. The experienced engineering team is familiar with US FDA validation requirements and Good Automated Manufacturing Practices 4.0. The company is certified to ISO 9001.
Assembly system features flexibility and ease of use
A flexible modular assembly system was presented by sortimat Technology GmbH & Co. (Winnenden, Germany) at the MEDTEC show in Stuttgart this March. This standardized assembly machine, called Jetwing, combines an assembly platform, functional stations, check and test stations, and transfer systems, all linked by standard interfaces. “Jetwing is a flexible modular system that can be modified to assemble a variety of products,” says Silke Fischer, head of marketing at sortimat. The standardized modules can be quickly and easily exchanged and modified, allowing manufacturers to respond rapidly to modifications in product design. To illustrate the point, sortimat will use the same platform at the Automatica trade fair on 15–18 June to assemble a completely different product. “At MEDTEC, we featured an installation that assembled an infusion set. At Automatica, we will use the same platform to assemble a syringe.”
The system allows up to 12 workstations to be directly configured, eliminating the need to adjust the cams below. Standard interfaces enable each module to be integrated with manual stations, feeder units, and palletizers. New technologies have also been introduced, allowing microdosing, unwinding, foil cutting and heat sealing, thermal moulding, and laser marking operations to be performed.
“More-complex products, such as multidose inhalers, need a lot of assembly steps,” says Fischer. In such cases, “a number of Jetwings can be linked up and connected to a central control panel, from which the operator can set machine parameters such as batch data and shift data.” Servodrives enable indexing times to be varied, allowing separate transfer and assembly speeds to be set for optimized processing. A new touch-screen colour display has been added to the line.
Microassembly cell is suitable for small device assembly applications
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A microassembly system can accommodate up to 16 pick-and-place units. Offered by
Mikron S.A. Boudry (Boudry, Switzerland), the G05 cell is a compact version of the company’s G05 platform. It operates at speeds up to 100 cycles per minute with an accuracy of ±10 µm, using 60 ¥ 60-mm pallets. The system is aimed at small-device assembly applications.
The use of proven technology and standardized interfaces, already available with the G05 concept, ensures reliability and service life. The G05 is Class 10,000 cleanroom compliant and meets GMP and US FDA guidelines.
Cleanroom moulding systems are offered
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Injection moulding machines with two-platen technology, developed by Krauss Maffei (München, Germany), offer a number of effective cleanroom solutions. These range from full integration of the machine in the cleanroom to installations in which only the cantilevered clamp unit protrudes into the cleanroom.
The company recently designed an automated manufacturing cell for Mapa GmbH (Zeven, Germany) for the production of a disposable baby bottle teat. The multicomponent injection moulding system uses a KM 150-390-160 CZ machine and a parts-removal robot. The parts are produced and packaged without operator intervention. The process takes place in a Class 100 cleanroom, which is itself embedded in a Class 10,000 cleanroom. Mapa decided on completely automated production in order to achieve the necessary low airborne-particle and biocontamination counts.
Copyright ©2004 European Medical Device Manufacturer
