EQUIPMENT NEWS
Modular assembly platform can be tooled to suit
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Developed following extensive consultation with medical device manufacturers for the purpose of gaining insight into their current needs, a modular linear assembly platform can be readily tooled and configured for the production of a wide range of devices. AGR Automation Ltd. (Arbroath, Tayside, UK) has made the Smartpod modular platform a high-tech shell from which an infinite variety of manufacturing cells can be built from an extensive range of application-specific tooling. A single line based on the platform can be as much as 12 m long, and it can be linked to other lines. Based on a synchronous electric (or magnetic) linear drive, the platform has configurable pallets that can move in continuous-motion and indexed formations simultaneously. Pallets can function as an x-axis, which enables flexibility and more-effective use of two- and three-axis pick-and-place units.
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The Smartpod is distinguishable from other flexible assembly platforms by its level of versatility and its sleek design. It comes as an enclosed white module that can be supplied as an untooled system ready to be configured for any number of assembly, test, packaging, and processing operations, or as a fully tooled system designed to carry out a specific application and integrating a wide variety of third-party proprietary equipment. The individual 1-m modules have eight pallet positions each, four along each side of the linear drive. Made of stainless steel and aluminium, the standard unit has a footprint of 4144 × 2000 mm and is 2.46 mm high. It features a fully interlocked guard system to ensure operator safety and is rated for Class 10,000 cleanroom operation. All systems are built to CE standards.
Modular software controls the pallet system and process stations. It enables the complete system to be configured and reprogrammed on the fly for maximum manufacturing flexibility. Further system flexibility is demonstrated by the fact that stations can be moved or changed over within 15 minutes. Modules can always be added or reconfigured to accommodate new products or processes.
Assembly systems accommodate integration of device safety features
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A designer and builder of automated assembly equipment prides itself on keeping pace with advances in medical device design and engineering. In particular, Kahle Automation (Caravaggio, BO, Italy) specializes in developing systems that are able to integrate the handling of various safety features that are increasingly being used with medical products. The firm routinely supplies machines to med-tech OEMs that have been designed to incorporate springs, protective caps, locking devices, self-destruct features, and related parts into medical assemblies.
The firm provides automated assembly and processing equipment to manufacturers of safety IV catheters, syringes, needles, scalpels, and other medical device and diagnostic products. In addition to custom equipment design, fabrication, and system integration, the company offers a full range of related validation, documentation, installation, and on-site maintenance services.
Modular assembly system is highly flexible
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A high-precision assembly system is designed to the customer’s specific requirements. The modularity of the Spaceline system from sortimat Technology GmbH (Winnenden, Germany) allows stations to be positioned freely, moved, or replaced. Developed to set high standards for flexibility, output, speed, and cost-efficiency, the system features a twin drive in 2, 3, or 4 indexing segments that can be configured in two assembly directions. Adaptation to product changes is quick and easy, and new-product lead times are very short.
Spaceline can be configured with 13 to 54 precise, reliable cam-driven stations and a maximum of 24 tracks. The system offers assembly speeds to 80 cycles per minute with extremely accurate positioning. Available with a variety of pallet sizes and a wide selection of standard functions, it is easy to integrate with downstream systems. Servomotors drive the indexed movement of pallets, which is rapid yet accurate. The assembly system comes with a newly designed human-machine interface and can be supplied with custom feeder systems.
Cartesian dispensing robot takes little bench space
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A benchtop dispensing robot handles a dispensing area of 8 × 6 in. and can store up to 100 job programs. Offered by I&J Fisnar France S.A. (Pontoise, France) to users for whom bench space and cost are important considerations, the I&J7100 Cartesian robot features step-by-step intuitive instructions that allow a program to be entered and running in minutes. A 16-channel input/output interface provides for communication with external devices, so that secondary applications or multiple pieces of dispensing equipment can be linked with the robot. Optional Windows software with a DXF file converter is available for programming from a personal computer, and a vision system package is offered optionally for automatic part location. The company also offers a range of hand or bench dispensers for single-part materials, and meter-mix equipment for two-part materials.
Control module diagnoses automated-line problems immediately
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An automation controller is designed to make diagnostic data gathered from production line components available immediately so that system downtime and maintenance and repair costs may be minimized. The CPX-FEC module from Festo AG & Co. KG (Esslingen, Germany) provides a direct link between automation and information technology (IT), allowing machines to be monitored from the office and configuration and diagnosis to be performed via the Internet. An integrated Ethernet interface facilitates the networking of automation components and gives users access to all standard IT services.
The basic CPX concept is integration of diagnostic functions. Controls and pneumatics are combined in valve terminals. The controller counts cycles to help in determination of maintenance requirements, and in the event of a breakdown it relays the error location. By enabling all critical values to be known, the module can eliminate downtime by triggering timely maintenance, controlling production sequences, and removing causes of line errors.
Diagnostic information and device status are visualized via a built-in Web server. Analysis by means of the TCP/IP protocol ensures transparency in matters involving process data. Also, e-mail and SMS text–enabled alarms keep users continually aware of exceed-limit values and other malfunctions.
Assembly machines are custom-built for medical tubing
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Fully automated assembly equipment and systems are designed and manufactured for the production of tubing-based medical devices. Basic operations performed by the systems from Tecnoideal S.r.l. (Mirandola, MO, Italy) include cutting tubing to length, attaching or solvent-bonding components, coiling and banding finished products, and leak testing. Average system productivity ranges from 1200 pieces per hour for complete tubing sets to as many as 5000 simple subassemblies an hour.
The company has produced custom automation systems for coiling tubing on a roller and fastening it with cohesive tape; a drip chamber with filter, spike, air vent, and cap; an injection point connector; tubing with a clamp, connector, and cap; a heparin line; tubing with a spike and accessories; and other complex products. In addition, an expanding capability in automation for the industrial market has resulted in the recent production of complete lines for the assembly and testing of valves, motors, and pumps. The manufacturer offers in-house expertise in software, mechanical engineering, and electronic engineering and maintains a network of specialized suppliers.
Most of these automatic assembly machines are controlled by a programmable logic controller with dedicated software. Custom electronics can be incorporated in the systems.
Vial inspection system operates at high speed
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An established pharmaceutical automation platform underlies a new system for the single-pass, high-speed inspection of lyophilized product in 3- to 30-ml vials. Available from ATS Automation (Munich), the compact Lyoscan vision system positively indexes vials in two successive turrets while cameras inspect the stopper, cap, body, and contents from the top, bottom, and sides at rates to 400 units per minute. The inspection process can identify as many as 17 defined standard faults in the product and the vial.
The system features specialized optics and tooling and can detect contaminants on a lyophilized surface or discoloration in a translucent liquid, capabilities not found in all inspection systems available to pharmaceutical manufacturers. It incorporates optimized Smartvision vision inspection tools. Windows-compatible process control provides fault-trending data that can be used to improve management of upstream processes; this software includes US FDA 21 CFR Part 11–compliant data-handling, security, and record-archiving functionality.
Designed for integration into a comprehensive production system, the Lyoscan offers real-time vial tracking with multiple fault-sorting options; rejected items are categorized for further disposition. Special technology facilitates rapid changeover of vial sizes.
Side-entry robot handles thin-walled moulded parts
A high-performance side-entry robot for injection moulding applications is capable of delivering thin-wall moulded parts from presses at speeds to better than 5.2 m/sec. Offered by Automated Assemblies Corp. (Clinton, MA, USA), the Raptor SE-310 comes in configurations suited to presses of 100–600 tn and can be supplied integrated into an in-mould labelling and decoration work cell or packaging system.Ultralight carbon-fibre end-of-arm tooling and patented InteliMotion dynamic motion control combine for responsive and repeatable part-handling capability. The robot features rigid steel-beam construction, offers a maximum payload capability of 33 lb and maximum traverse of 118 in., and has a controller that governs robot and work cell input/output, vision, network communications, and user programming.
Multiple-camera Raptor Vision is available as an integrated part-inspection option. The reliable process verification system can be mounted on the floor or tabletop or overhead and comes in single- and double-arm configurations.
