Showstoppers
A selection of innovative new products and services exhibited at Hannover Messe 99 (Germany) and MD&M East 99 (New York, NY, USA)
Manufacturing equipment
Cleanroom-compatible machine assembles inhaler
A supplier of standard and custom production equipment for medical products has designed a machine for the assembly of an inhalation device. Sortimat Technology GmbH & Co. (Winnenden, Germany) exhibited the machine at Hannover Messe 99, where it was shown assembling the Unitdose inhaler system developed and moulded by Pfeiffer GmbH for Glaxo Wellcome.
The machine, which assembles the needle jig and needle within the moulded nasal actuator, ensures 100% quality control after each step and ejects final samples for quality assurance processes at random or selected intervals. The rotary indexing equipment, which uses a gearmotor-driven mechanical cam system, assembles approximately 80 parts per minute. A reduction in energy consumption was one of the factors influencing the design of this machine and is indeed a priority in all of the company's projects.
Designed for use in a Class 1000 cleanroom, the machine is constructed primarily of stainless steel. Even the bowl feeders are made of electroplated stainless steel, which facilitates cleaning, adds sortimat marketing manager Silke Fischer. "Bowl feeders are often coated with polyurethane, but this material cannot withstand aggressive cleaning liquids," she notes. "We are always looking for ways to prevent creating dust and to avoid the use of abrasive parts in our machines. That has become an important requirement as we develop equipment for use in Class 100 cleanrooms," adds Fischer. Other features of the unit include sensors that check for product integrity and a sophisticated vision system as well as low energy consumption.
Sortimat has developed assembly systems for a variety of other medical products including dialysis sets, dispensing and metering pumps, disposable needles and syringes, safety syringes, catheters, and infusion and transfusion sets. Feeders, labelling systems, adhesive dispensers, inspection systems, coiling units, welders, laser markers, and printers are available.
Machine vision
Miniature camera captures 60 images per second
When coupled with a digital signal processing (DSP) image analyzer system, a compact yet rugged high-speed digital camera serves as a high-performance machine vision tool for various applications. The product was presented at Hannover Messe 99 along with a range of other machine vision systems developed by Fastcom Technology S.A. (Lausanne, Switzerland).
The StereoCam accepts both CS- and C-mount lenses, the latter with an adapter ring, and all signals pass through a single cable. Devoid of DIP switches and buttons, the camera is entirely controlled and configured by means of software that uses the company's DSP image analysis system. Two digital cameras can be interfaced via the image analyzer system, which includes a high-performance floating-point DSP with rapid memory capabilities. Up to 60 full-resolution images can be captured per second.
The StereoCam was initially designed for use with automated dispensing equipment in the diagnostics field, says Nikolaus Schibli, a partner in the company. "The application involved the use of a robotic arm to dispense powders and granules into reagents," Schibli explains. "The arm was guided by an operator, but we were able to increase productivity by installing a small camera on the robotic arm and using algorithms to automatically position it above the reagent."
The company also offers a machine vision apparatus that integrates image capture and processing functions within a single package. The MVS-135 can be used to read bar codes, identify components and ensure that they are positioned correctly, and perform a number of other industrial inspection operations.
Metrology equipment
Instrument performs noncontact roughness, contour, and topography measurements
Described as an instrument that bridges the gap between profiling and scanning probe microscopy, a metrology device combines roughness, contour, and topography measurement capabilities in a noncontact, nondestructive package. Developed by Fries Research & Technology GmbH (Bergisch-Gladbach, Germany), the MicroGlider was featured in the Innovations and Research & Technology Pavilion at Hannover Messe 99.
The instrument incorporates a noncontact stylus suited for high-resolution topographical measurements and an optical sensor designed to perform rapid surface analyses. A large imaging range in the x-, y-, and z-axes were built into the MicroGlider to facilitate industrial applications, adds general manager Thomas Fries. Complementary software enables automated data acquisition and evaluation in a user-friendly format, and a wide range of view options can be selected.
The company has developed several sensors that can be integrated into the MicroGlider simply by changing the measuring heads. Sensors suited for the measurement of eddy current signals, hardness on the micrometric or nanometric scale, and white-light interferometry are available. More sensors are under development.
In the medical device field, " the MicroGlide has been used to measure and analyze everything from stents and contact lenses to prostheses," says Fries.
Manufacturing equipment
Pick-and-place system achieves 120 cycles per minute
A supplier of robotic systems exhibited what is reportedly the fastest pick-and-place system in the world at Hannover Messe 99. The FlexPicker, designed and manufactured by ABB Automation Group Ltd. (Zürich, Switzerland) can pick and place two parts within one second, according to sales representative Rafiq Iqbal. The system was shown at the exhibition incorporating a battery charger into a mobile phone, "but it is suited for any high-volume product weighing less than a kilo," says Iqbal. "Pharmaceuticals and syringes are perfect applications," he adds.
ABB, which provides flexible automation solutions to a variety of industries, is currently working on a washdown system suited for cleanroom use, according to Iqbal. The company has installed more than 70,000 robots worldwide and is represented in 30 countries.
Electronic components
Resistive touch screens introduced for portable devices
Four-wire resistive touch screens suited for use in portable medical equipment feature low power requirements and small-format displays that recognize touch by stylus, pen, or finger. The TouchTek 4 line was introduced at Hannover Messe 99 by MicroTouch Systems Ltd. (Abingdon, Oxon, UK).
The screen surface is coated with a durable conductive material that resists scratches without impeding optical clarity. To facilitate OEM integration of the product, MicroTouch has introduced a 61.9 X 33.2-mm serial controller that interfaces with the company's software drivers compatible with most leading operating systems.
MicroTouch focusses on incorporating optical quality and durability into the touch screens, says European product manager Robin Dyer, because these are the key attributes sought by OEMs manufacturing portable devices.
Motion control components
Ball screw combines speed and power
Launched at Hannover Messe 99, a cold-rolled high-helix ball screw features optimized travel speed, wear resistance, and a high pitch at about a quarter of the cost of similarly sized machine-ground ball screws. The Carry Speed-Line, which has a nominal screw diameter of 16 mm and a 50-mm pitch, is supplied by Eichenberger Gewinde AG (Burg, Switzerland), a company that specializes in the conversion of rotary into linear motion and vice versa.
Optimized production processes and advanced technology have enabled the firm to produce the ball screw at a fraction of the cost of competing products, says sales representative Carmela Hediger. In fact, the product is deemed sufficiently cost-effective that the company plans to export the Carry Speed-Line to countries such as Taiwan and Korea.
The component is available in a standard design comprising a flange nut and screw and bearing mechanism; special designs can be accommodated. The company is certified to ISO 9001.
Manufacturing equipment
Flexibility is key feature of modular line-scan cameras
A company that specializes in equipment for physical measurement applications has developed a line of compact intelligent line-scan cameras that are suited for use in industrial imaging. Messgeräte für Medizin- und Umweltechnik (Wedel, Germany) presented its ILS camera line at Hannover Messe 99.
Because of their modular architecture, the systems can be configured to suit specific applications. Monochromatic or colour image sensors with varied resolutions, sensitivities, and speeds can be combined with control and digitizing modules to generate analogue and digital video signals. "The digitizer and a high-performance image processor can be integrated into the camera," adds engineer Ulrich Wachholz, "which avoids having to add components to the back end of the device." Various I/O modules enable easy integration of the unit into standard industrial control systems.
The company also provides an array of services to device OEMs, including contract research and development, prototyping, production engineering, and software and hardware production. Particular expertise lies in analogue and digital electronics, measurement technology, sensors, optics, and electromagnetic compatibility issues.
Prototyping
Machine vision specialist develops full-body scanner
A company with extensive experience developing custom image processing systems for a cross section of industries has produced a 3-D full-body scanner that can perform measurements in a few seconds. The product, which was presented by Vitronic (Wiesbaden, Germany) at Hannover Messe 99, has key applications in medical technology and reverse engineering, according to R&D manager Dirk Förtsch.
Most 3-D measuring technologies require the subject to remain immobile for long periods of time or can scan only clearly defined contours. By using laser split-beam technology, however, the Vitus system scans the body in 6–21 seconds, depending on the desired resolution. Meanwhile, images captured by as many as 24 camera and laser setups are recorded and evaluated in real time. The resulting 3-D measurement points, which have an approximate 1–2-mm resolution, are processed to form a 3-D CAD model.
In addition to reverse engineering and numerous industrial applications, the scanners may serve a useful function in the medical technology sector, says Förtsch. "Much in the same way that the scanner can be used to produce made-to-measure clothing with a precision unmatched by any tailor, it can enhance the fabrication of prosthetic and orthopaedic devices," he says. Bandaging for badly burned patients could also be designed with extreme accuracy, and the patients would suffer no unnecessary discomfort because the scanner performs contact-free measurements.
A supplier of custom vision equipment, Vitronic's product range includes systems designed for optical quality and surface inspection, 3-D on-line measurement, character recognition, bar code processes, and robotic vision.
Tube-sealing equipment
RF generator and handheld sealer offer large seal size for dry and filled tubing
An RF sealing system can be used to seal dry or liquid-filled tubing up to ½ in. OD. "This unit doubles the size of sealable product, which should provide an advantage over previous models," notes Judi Laurel, marketing associate at SEBRA (Tucson, AZ, USA). The system, which comprises an RF generator and a handheld, midsized pneumatic sealing head, is CE marked and is suited for use on closed plastic systems in medical applications including synthetic cell and tissue research, large-volume biopharmaceutical fluid processing, and culture media processing. SEBRA exhibited the system at MD&M East 99.
The Model 3120 generator is capable of 200-W output and ensures correct operation for all ac single-phase input voltages from 90 to 264 V. The operator can control RF power, RF dwell time, and clamp time manually via the front panel. RF dwell time can also be set automatically by an external controller.
The Model 3806 sealing head features matching network, air cylinders, and 8-ft RF and pneumatic lines. A built-in clamping feature holds tubing secure during the sealing process. Tubing made from materials such as polyvinyl chloride, EVA, polyurethane, and some nylons can be sealed.
Materials
Implant-grade polymer launched
A new grade of polyaryletherketone (PEEK) resin suitable for use in implants began its global launch at MD&M East 99. PEEK-Optima LT is reportedly the first high-performance thermoplastic that can be used in long-term hip, spinal, and dental implants.
The material combines biocompatibility with the basic characteristics of the PEEK family, including purity, fatigue resistance, good mechanical properties, and resistance to hydrolysis and a broad range of chemicals. "A significant advantage in medical engineering is that PEEK-Optima LT can be tailored to match the stiffness and impact performance of human bone," says Jörg Schlegel, medical market developer at Victrex plc (Thornton Cleveleys, Lancs, UK). The polymer is backed by extensive certification, including biocompatibility test results in compliance with EEC Directive 90/128/EEC and USP Class VI requirements, as well as FDA master files.
PEEK-Optima LT withstands sterilization by autoclave, EtO, and irradiation. Radiotranslucence allows for inspection by x-ray and CT scanning, and the material can be rendered radiopaque with the addition of special fillers. The material is suited for the production of both large and high-precision parts. Easy processing allows the material to fill ultrathin walls in products such as heart valve components.
The company supplies two grades for both injection-moulded and extrusion applications.
Electronic components
Microvalve suited for dosing applications
A two-way microvalve manufactured by means of silicon micromachining incorporates a chemically resistant rubber membrane and a small machined actuator. The product was presented by Twente MicroProducts (Enschede, Netherlands) at Hannover Messe 99.
The bistable valve has two fixed positions, so only switching power is required. The component has an internal volume of less than 5 µl and the valve opening on current prototypes is 0.2 mm. The design can be modified to suit specific customer requirements.
The microvalve is suited for dosing applications in the medical and chemical sectors. It can be mounted on a channel board to perform dosing and detection functions in the millilitre to nanolitre range for lab-on-chip–type applications.
