ISOLATOR SYSTEM AND METHOD

Abstract

A barrier system having a restricted-access environment, such as an isolator, a feeding apparatus for feeding closure elements into the isolator, a sealing station for sealing containers using the closure elements, and a handling device for transferring the closure elements. The sealing station and the handling device are arranged within the restricted-access environment, and the handling device is configured to transfer a fed closure element from the feeding apparatus to an inspection position within the restricted-access environment. The barrier system may also have an inspection device configured to inspect the closure element at the inspection position and determine whether the closure element has a defect. The handling device is configured to transfer the closure element from the inspection position to the sealing station when the closure element has no defect. Also disclosed is a method for processing closure elements in a restricted-access environment.

Claims

1. A barrier system, the barrier system comprising: a restricted-access environment, a feeding apparatus for feeding closure elements into the restricted-access environment, a sealing station for sealing containers using the closure elements, and a handling device for transferring the closure elements, the sealing station and the handling device are arranged within the restricted-access environment, the handling device is configured to transfer a fed closure element from the feeding apparatus to an inspection position within the restricted-access environment, wherein the barrier system further comprises an inspection device, the inspection device is configured to inspect the closure element at the inspection position and to determine whether the closure element has a defect, and the handling device is configured to transfer the closure element from the inspection position to the sealing station when the closure element has no defect.

2. The barrier system according to claim 1, wherein the feeding apparatus is configured to provide the closure elements on a surface, and the handling device is configured to transfer the closure element from the surface to the inspection position.

3. The barrier system according to claim 1, wherein the barrier system further comprises a disposal device for disposing of defective closure elements, and the handling device is configured to transfer the closure element from the inspection position to the disposal device when the closure element has a defect.

4. The barrier system according to claim 1, wherein the barrier system further comprises a control device for controlling the handling device, and the inspection device comprises the control device and the control device is further configured to determine whether the closure element has a defect.

5. The barrier system according to claim 1, wherein the inspection device further comprises a camera system, the camera system is configured to capture at least one image of the closure element at the inspection position, and the inspection device is configured to determine, on the basis of the at least one captured image, whether the closure element has a defect.

6. The barrier system according to claim 1, wherein the closure elements are formed with a substantially circular cross-section, and the inspection device is configured to inspect the closure element at the inspection position for its roundness.

7. The barrier system according to claim 6, wherein the inspection device is configured to determine, on the basis of the at least one captured image, a parameter which indicates a measure for the roundness of the closure element, and to determine, on the basis of a comparison of the determined parameter with a threshold value, whether the closure element has a defect.

8. The barrier system according to claim 6, wherein the inspection device is configured to determine whether an outer edge of the closure element lies within a tolerance range in the captured image.

9. The barrier system according to claim 1, wherein the sealing station is a crimping station, and the closure elements are crimp caps.

10. A method for processing closure elements in a restricted-access environment, comprising the steps of: feeding the closure elements into the restricted-access environment by means of a feeding apparatus; first transferring a fed closure element from the feeding apparatus to an inspection position within the restricted-access environment by means of a handling device; inspecting the closure element at the inspection position by means of an inspection device, wherein the inspection device determines whether the closure element has a defect; second transferring the closure element from the inspection position to a sealing station within the restricted-access environment by means of the handling device, when the closure element has no defect; and sealing a container in the sealing station by means of the closure element transferred to the sealing station.

11. The method according to claim 10, wherein in the feeding step the feeding apparatus provides the closure elements on a surface, and in the first transferring step the handling device transfers the closure element from the surface to the inspection position.

12. The method according to claim 10, wherein the method further comprises the steps of: third transferring the closure element from the inspection position to a disposal device within the restricted-access environment by means of the handling device, when the closure element has a defect; and disposing of the closure element transferred to the disposal device by means of the disposal device.

13. The method according to claim 12, wherein in the inspecting step a camera system of the inspection device captures at least one image of the closure element at the inspection position, and the inspection device determines, on the basis of the at least one captured image, whether the closure element has a defect.

14. The method according to claim 10, wherein the closure elements are formed with a substantially circular cross-section, and in the inspecting step the inspection device inspects the closure element at the inspection position for its roundness.

15. The method according to claim 14, wherein the inspection device determines, on the basis of the at least one captured image, a parameter which indicates a measure for the roundness of the closure element, and determines, on the basis of a comparison of the determined parameter with a threshold value, whether the closure element has a defect.

16. The method according to claim 14, wherein the inspection device determines whether an outer edge of the closure element lies within a tolerance range in the captured image.

17. The method according to claim 10, wherein the sealing station is a crimping station, and the closure elements are crimp caps.

Description

DRAWINGS

[0078] Exemplary embodiments of the disclosure are illustrated in the drawings and are explained in more detail in the following description. The figures show:

[0079] FIG. 1 a schematic view of a first embodiment of an isolator system;

[0080] FIG. 2 an isometric view of a second embodiment of an isolator system;

[0081] FIG. 3 a side view of the isolator system from FIG. 2 showing an inspection position;

[0082] FIG. 4A a schematic view of a closure element with a circular outer contour;

[0083] FIG. 4B a schematic view of a closure element with an elliptical outer contour;

[0084] FIG. 4C a schematic view of a closure element with a dented outer contour;

[0085] FIG. 4D a schematic view of a closure element with a crack;

[0086] FIG. 5A a schematic view of a round closure element;

[0087] FIG. 5B a schematic view of a dented closure element; and

[0088] FIG. 6 a schematic view of an embodiment of a method for processing closure elements in an isolator.

DETAILED DESCRIPTION

[0089] FIG. 1 shows a first embodiment of an isolator system as a barrier system, designated in its entirety by reference numeral 10.

[0090] The isolator system 10 comprises an isolator 12. The isolator is a restricted-access environment. The isolator 12 comprises an interior 14. The isolator 12 further comprises a transfer system 16. The transfer system 16 may be configured as an alpha-beta port system. The transfer system 16 comprises a port 18. The port 18 may be an alpha port. The port 18 is arranged on a wall of the isolator 12 that separates the interior 14 from an external environment. The port 18 may comprise an isolator opening and an isolator door. The isolator door may be arranged at the isolator opening. By means of the isolator door, the isolator opening can be opened or closed. From the outside, a transfer chamber 20 can be coupled to the port 18. The transfer chamber 20 may be configured as a beta container or beta port. Closure elements 22 may be arranged or provided in the transfer chamber 20.

[0091] The isolator system 10 comprises in the interior 14 of the isolator 12 a feeding device 24, a sealing station 34, a disposal device 42, and a handling device 46. The feeding device 24 serves to feed the closure elements 22 into the isolator 12. The handling device 46 serves to transfer the closure elements 22 within the isolator 12. The sealing station 34 serves to seal containers using, in particular, non-defective closure elements 22. The disposal device 42 serves to dispose of, in particular, defective closure elements 22.

[0092] The isolator system 10 may further comprise in the interior 14 a filling station, not shown. In this filling station, the containers can be filled, for example with a pharmaceutical or cosmetic substance, before they are sealed in the sealing station 34. The isolator system 10 may further comprise additional, not shown, handling devices in the interior 14 for handling the closure elements and/or the containers. These may be used, for example, to transfer the containers from the filling station to the sealing station 34.

[0093] By means of the feeding device 24, the closure elements 22 can be fed into the interior 14 of the isolator 12. The closure elements 22 can be provided outside the isolator in the transfer chamber 20 and then introduced into the isolator 12 via the port 18 and the feeding device 24. The feeding device 24 comprises a surface 26. The feeding device 24 may comprise, for example, a feeding unit 28, a first vibrating plate 30, and a second vibrating plate 32.

[0094] The feeding unit 28 may serve to feed the closure elements 22 from the port 18 onto the first vibrating plate 30. The feeding unit 28 may, for example, be connectable to the port 18 from the inside. In particular, by means of the feeding unit 28, closure elements can be introduced from a transfer chamber 20 into the isolator 12 via the port 18 and the feeding unit 28 and be fed to the first vibrating plate 30.

[0095] The first vibrating plate 30 may serve to convey the closure elements 22 onto the second vibrating plate 32. For this purpose, the first vibrating plate 30 may comprise a first drive unit and a first plate. The first plate serves as a support surface for the closure elements 22. In particular, the closure elements 22 can be fed onto the first plate and conveyed on it. The first drive unit is configured to move the first plate. In particular, the first drive unit is configured to tilt and vibrate the first plate. The conveying of the closure elements may be carried out by vibrating the first plate.

[0096] The second vibrating plate 32 may serve to arrange the closure elements 22 on the second vibrating plate 32 in a defined position, in particular to orient them. For this purpose, the second vibrating plate 32 may comprise a second drive unit and a second plate. The second plate serves as a support surface for the closure elements 22. In particular, the closure elements 22 can be fed onto the second plate and moved thereon. The second drive unit is configured to move the second plate. In particular, the second drive unit is configured to vibrate the second plate. The arrangement or orientation of the closure elements in the defined position can be achieved by vibrating the plate. In this way, the closure elements are provided in the defined position on the second vibrating plate 32. Closure elements 22 provided in this defined position can then be picked up by the handling device 46 and transferred to the sealing station 34. The surface 26 can thus be a surface of the second plate of the second vibrating plate 32.

[0097] In the sealing station 34, containers filled with a product are sealed with the fed closure elements 22. For sealing the containers, the sealing station 34 comprises a sealing device 36. The sealing device 36 may be a crimping device, by means of which crimp caps can be applied to the containers as closure elements. Alternatively, the sealing device 36 may also be a stopper placing device, by means of which stoppers can be placed onto the containers as closure elements. The sealing station 34 may additionally comprise a storage device 38 in which the closure elements can be temporarily stored or held prior to sealing. The sealing station 34 may further comprise a separate handling device 40 by means of which the closure elements 22 can be picked up from the storage device 38 and placed onto the containers.

[0098] The disposal device 42 can be used to dispose of defective closure elements 22. For this purpose, the disposal device 42 may comprise a collection container 44. Defective closure elements 22 can be collected in the collection container 44.

[0099] The handling device 46 serves to handle the closure elements 22 within the interior 14 of the isolator 12. In particular, the handling device 46 can pick up the fed closure elements 22 individually or in pairs from the feeding device 24, in particular from the surface 26, and transfer them to the sealing station 34 or to the disposal device 42. The handling device 46 is preferably configured as a handling robot. The handling device 46 may comprise a multi-axis arm 48 and an end effector 50. The end effector 50 is arranged at one end of the arm 48. The arm 48 can be moved by means of a drive unit. The end effector may comprise a gripping tool, for example one or more grippers, by means of which one or more closure elements 22 can be gripped for transfer, in particular picked up and held, preferably one per gripper.

[0100] The isolator system 10 may further comprise a camera system 52. The camera system 52 is preferably arranged on a ceiling of the isolator 12. For example, the camera system 52 may be mounted on the ceiling of the isolator 12. Using the camera system 52, images can be captured. To capture the images, the camera system 52 may comprise one or more cameras 54. The camera system 52 may also comprise a lighting unit by means of which at least the area to be captured during image acquisition is illuminated. The camera system 52 may in particular be arranged such that the feeding device 24, the sealing station 34, the disposal device 42, and a working area of the handling device 46 lie within the field of view of the camera system 52. For example, the camera system 52 may be configured to capture an image of the closure elements on the first and/or second vibrating plate 30, 32. Furthermore, the camera system 52 may be configured to capture an image of the closure elements 22 during the transfer of the closure elements, i.e., in the working area of the handling device 46.

[0101] The isolator system 10 may further comprise a control unit 56. The control unit 56 serves to control the handling device 46. In particular, the control unit 56 controls the transfer of the closure elements 22 from the feeding device 24 to the sealing station 34 or to the disposal device 42. The control unit 56 may further be configured to control the first and/or second vibrating plate 30, 32 to provide the closure elements 22 on the surface 26, i.e., on the second vibrating plate 32, in a defined quantity and/or in a defined position, in particular orientation.

[0102] The control unit 56 may be configured to control the camera system 52. In particular, the control unit 56 may control the image acquisition of the camera system 52 for capturing images. The control unit 56 controls the handling device 46 and optionally also the vibrating plates 30, 32 based on the captured images, i.e., based on the image data, of the camera system 52. In particular, the control unit 56 may be configured to evaluate the captured images. For example, the control unit 56 may determine based on the captured images whether a closure element 22 is arranged on the second vibrating plate in the defined position.

[0103] For this purpose, the control unit 56 may comprise various subunits, each of which performs control of a component and/or processing of data. For example, the control unit may comprise a control unit that controls the handling device 46, the camera system 52, or optionally also the vibrating plates 30, 32. The control unit may send control commands to the respective components for controlling them. Furthermore, the control unit may comprise a data processing unit configured to evaluate the captured images of the camera system. The data processing unit may, for example, determine the position of closure elements on the second vibrating plate 32 based on the captured images.

[0104] The control unit 56 may be connected to or comprise a non-volatile data memory in which a computer program is stored. In some embodiments, the control unit 56 is a general-purpose computer, such as a commercially available personal computer running Windows, Linux, or macOS, and the computer program from memory includes program code designed and configured to implement control and determination steps. In an alternative embodiment, the control unit 56 is a logic circuit, such as a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), a microcontroller, or any other suitable programmable electronic circuit. In such a logic circuit, control and determination steps can be implemented. Any suitable programming language or hardware description language, such as C, VHDL, or the like, can be used for implementing the control and determination steps in the logic circuit.

[0105] The isolator system 10 further comprises a control device 66. The control device 66 serves to inspect a closure element 22 at an inspection position 58 within the isolator 12 and to determine whether the closure element 22 has a defect. The inspection position 58 is arranged in a working area of the handling device 46. Preferably, the control device 66 comprises the control unit 56 of the isolator system 10. In particular, the control unit 56 may be configured to determine whether a closure element 22 arranged at the inspection position has a defect.

[0106] The handling device 46 is configured to transfer the closure elements individually or in pairs from the feeding device 24 to the inspection position 58. The transfer to the inspection position 58 is illustrated in FIG. 1 by the arrow with reference numeral 60. At the inspection position, the control device 66 then determines whether the closure element 22 transferred to the inspection position 58 has a defect. If the inspection determines that the closure element 22 has no defect, the closure element 22 is further transferred to the sealing station 34. The transfer to the sealing station 34 is illustrated in FIG. 1 by the arrow with reference numeral 62. If the inspection determines that the closure element 22 has a defect, the closure element 22 is transferred to the disposal device 42. The transfer to the disposal device 42 is illustrated in FIG. 1 by the arrow with reference numeral 64.

[0107] The camera system 52 may be part of the control device 66. In particular, the camera system 52 may be configured to capture at least one image of a closure element 22 at the inspection position 58. In particular, the inspection position 58 may be arranged below the camera system 52 within the field of view of the camera system 52. The control device 66 may then determine, based on the at least one captured image, whether a closure element 22 arranged at the inspection position 58 has a defect. In particular, the control unit 56 may be configured to determine, based on the at least one captured image of the camera system, whether the closure element 22 has a defect. Based on the result of this determination, the control unit 56 may then control the handling device 46 accordingly.

[0108] FIG. 2 shows a second embodiment of the isolator system 10 as a barrier system. The isolator system of the second embodiment essentially corresponds to the isolator system 10 of the first embodiment from FIG. 1. Identical elements are designated with identical reference numerals and are not explained further.

[0109] In the isolator system 10 of the second embodiment, the sealing station 34 is configured as a crimping station, and the sealing device 36 is configured as a crimping device. Accordingly, the closure caps 22 are configured as crimp caps. Furthermore, the camera system 52 is arranged in the isolator 12 on the ceiling. In particular, the collection container 44 is arranged adjacent to the feeding device. In particular, the camera system 52 is arranged above the collection container 44 and the feeding device 24.

[0110] FIG. 3 shows, by way of example, the position of the inspection position 58 in the isolator system 10 from FIG. 2. In particular, the camera system 52 is arranged in a vertical direction 68 above the collection container 44. Between the camera system 52 and the collection container 44, the inspection position 58 is arranged in the vertical direction 68. The inspection position 58 is in particular arranged above the collection container 44 in the vertical direction.

[0111] As previously explained in connection with the isolator system 10 of the first embodiment, each closure element 22 is first transferred by the handling device 46 to the inspection position 58 in order to be inspected there by the control device 68. For this purpose, the camera system 52 may capture an image of the respective closure element 22 arranged at the inspection position 58 from above. The control unit 56 may then determine, based on the captured image, whether the closure element 22 has a defect. If the inspection reveals that the closure element 22 has no defect, the handling device 46 transfers the closure element 22 further to the sealing station 34. If the inspection reveals that the closure element 22 has a defect, the handling device 46 transfers the closure element 22 further to the disposal device 42. For this purpose, the handling device 46 may simply release the defective closure element 22 and let it drop into the collection container 44 arranged below the inspection position 58.

[0112] FIG. 4A shows, by way of example, a top view in the axial direction of a closure element 70 with a circular cross-sectional geometry perpendicular to the axial direction. The outer contour is round or circular in this case.

[0113] FIG. 4B shows, by way of example, a top view in the axial direction of a deformed closure element 72 with an elliptical cross-sectional geometry perpendicular to the axial direction. The outer contour in this case is not round but elliptical with an eccentricity greater than zero. Such an outer contour may result, for example, if a round closure element is gripped with a gripper and slightly compressed in the process.

[0114] FIG. 4C shows, by way of example, a top view in the axial direction of a deformed closure element 74 that has an essentially circular cross-sectional geometry, wherein the closure element 74 has a dent 76 on the outside. In the region of the dent 76, the cross-sectional geometry deviates from the circular shape.

[0115] FIG. 4D shows, by way of example, a top view in the axial direction of a closure element 78 with a circular cross-sectional geometry perpendicular to the axial direction. The closure element 78 has a crack 80 on the top side.

[0116] The control device 66 of the first and second embodiments of the isolator system 10 can inspect the closure elements 22 for one or more defects. The one or more defects are preferably an insufficient roundness of the closure element and/or a crack in the closure element.

[0117] The closure elements 22, in particular crimp caps, are formed with an essentially circular cross section perpendicular to the axial direction, i.e. with a round outer contour. The control device 66 may then be configured to inspect each closure element 22 at the inspection position 58 for its roundness. The camera system then captures at least one image of the closure element 22 at the inspection position 58. The control unit 56 then determines, based on the at least one captured image, a parameter that indicates a measure of the roundness of the closure element. The control unit 56 then determines, based on a comparison of the determined parameter with a threshold value, whether the closure element has a defect.

[0118] Preferably, the handling device 46 arranges each closure element 22 to be inspected at the inspection position 58 in a defined orientation, in particular in such a way that an image plane of the captured image is perpendicular to the axial direction of the closure element.

[0119] To inspect the roundness, the control unit 56 may in particular first determine an outer contour of the closure element 22 in the captured image and fit a circle to the outer contour. Then the control unit 56 can determine the quality of the fit of the circle, wherein the quality is a measure of the roundness of the closure element. If the quality is lower than the threshold value, the closure element has a defect, i.e. insufficient roundness.

[0120] Alternatively, to inspect the roundness, the control unit 56 may determine an outer contour of the closure element 22 in the captured image and fit a closed curve to the outer contour. Then the control unit 56 may determine the variation, i.e. variance, of the curvature along the closed curve, wherein the variation is a measure of the roundness of the closure element. If the variation is greater than the threshold value, the closure element has a defect, i.e. insufficient roundness.

[0121] Alternatively, to inspect the roundness, a reference image showing a round closure element may be used, see for example FIG. 4A. The deviation of the outer contour of the image of the closure element 22 in the captured image from the outer contour of the image of the round closure element in the reference image may then be used as a measure of the roundness of the closure element. The control unit 56 can then determine this deviation by image comparison. If the deviation is greater than the threshold value, the closure element 22 has a defect, i.e. insufficient roundness.

[0122] To inspect the closure element 22 for a crack, a reference image of a closure element without a crack may also be used, for example. The control unit 56 can then also determine whether the closure element 22 has a crack by comparing the captured image with the reference image.

[0123] Alternatively, to inspect the roundness, it can also be determined whether an outer contour or an edge of the closure element 22 in the captured image lies within a tolerance range between a first circle 82 and a second circle 84. This is illustrated by way of example in FIGS. 5A and 5B.

[0124] The first circle 82 and the second circle 84 are arranged concentrically around a common center. The first circle 82 is larger than the second circle 84. The area between the first circle 82 and the second circle 84 may be referred to as a tolerance range or tolerance band. If the outer edge of the closure element 22 to be inspected lies completely within the tolerance range, the closure element is sufficiently round and thus not defective. If the outer edge of the closure element 22 to be inspected lies partially or completely outside the tolerance range, the closure element is not sufficiently round and thus defective.

[0125] In FIG. 5A, a closure element is shown whose outer edge 86 lies completely within the tolerance range. This closure element is therefore not defective. In FIG. 5B, a closure element is shown whose outer edge 90 lies partially outside the tolerance range. This closure element is therefore defective.

[0126] To determine whether the outer edge lies within the tolerance range, the area of the image around the center may be divided into segments 88. In FIGS. 5A and 5B, the area is divided into sixteen segments 88-1, 88-2, . . . , 88-16. The individual segments are shown as dashed lines. For each segment 88, it is determined whether a pixel of the outer edge in the segment lies within the tolerance range. If a pixel of the outer edge lies within the tolerance range in all segments 88, the closure element is not defective. However, if there is no pixel within the tolerance range in at least one segment 88, the closure element is defective.

[0127] In FIG. 5A, a pixel of the outer edge 86 lies within the tolerance range in each segment 88. In FIG. 5B, no pixel of the outer edge 86 lies within the tolerance range in segments 88-1 and 88-2.

[0128] FIG. 6 shows an embodiment of a method for processing closure elements 22 in an environment with restricted access, in particular in an isolator 12, designated in its entirety with reference numeral 100. The method 100 can be carried out using the isolator system 10 according to the first or second embodiment.

[0129] In a first step 102 of the method 100, the closure elements 22 are fed into the isolator 12 by means of the feeding device 24.

[0130] In a further step 104 of the method 100, a fed closure element 22 is transferred by means of a handling device 46 from the feeding device 24 to the inspection position 58.

[0131] In a further step 106 of the method 100, the closure element 22 transferred to the inspection position 58 is inspected at the inspection position 58 by means of the control device 66, wherein the control device 66 determines whether the closure element 22 has a defect.

[0132] In a further step 108 of the method 100, the inspected closure element 22 is transferred by means of the handling device 46 from the inspection position 58 to the sealing station 34, if the closure element 22 has no defect.

[0133] In a further step 110 of the method 100, a container is sealed in the sealing station 34 by means of the closure element 22 transferred to the sealing station 34.

[0134] In a further step 112 of the method 100, the inspected closure element 22 is transferred by means of the handling device 46 from the inspection position 58 to the disposal device 42, if the closure element 22 has a defect.

[0135] In a further step 114 of the method 100, the closure element 22 transferred to the disposal device 42 is disposed of by means of the disposal device 42.

[0136] It is to be understood that the foregoing is a description of one or more preferred exemplary embodiments of the invention. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.

[0137] As used in this specification and claims, the terms for example, e.g., for instance, such as, and like, and the verbs comprising, having, including, and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.