June 19, 2017

Reservoir Assembly Machine

Machine No. 5957

Most insulin packs come in a pre-measured syringe that the patient uses to inject themselves. This machine assembles the plunger, stopper, and two o-rings into a barrel, along with a septum and snap cap that seals off the inside of the syringe from the distal end. It then places a transfer guard onto the septum end and orients it radially. The machine operates around a precision link indexer that produces two complete and tested syringes at a time. Each of the stations’ main actuation is driven off of a cam connected to the main indexer. This allows for complete accuracy in timing stations with the indexing of the nests that support the assemblies. The barrels are lubricated and installed over the plunger assembly and the finished assemblies are actuated back and forth to make sure they operate correctly.

Machine Status Monitoring
A diagram of your machine will be used to monitor the machine status. Weight, force, location, and temperatures are displayed in real time on a pull-down screen when monitored by such devices.
Production Data Storage
With the HMI, production information is stored. You can modify the data table to store most all of the machine information available. This includes overall production by Lot, Shift, Weekly, Monthly, and even Total. Information concerning machine function is useful in that it tracks system operations and displays the number of attempts, failures, and machine stoppages. This information is critical for problem-solving by your technicians. All stored information can be uploaded to a storage device for long-term data collection.
Password Protected Modes of Operation
The HMI also allows you to run in several different modes of operation along with controlled access to these modes. This allows for operator clearing of error codes, halting the machine to clear a jam, and to purge all product at the end of the lot. Engineering and Manufacturing access allows for supervisory updates and product code alterations when required, along with process code updates by trained engineering staff. Engineers may also run the machine is a step mode to verify process steps and hardware malfunctions when troubleshooting a problem.

Fault Diagnosis
Notification screens make it easy for the operator to diagnose and locate possible faults during production runs. Red & green highlights on each station notify the operator that the machine is running as required, or that there is a system fault. The message screen tells the operator what the cause of the fault is and highlights the station it’s on.
Sequence & Timing Data Tables
Sequence timing delays and/or counts between operations can be changed to allow for more time between steps when part configurations differ slightly and cause systems to run slower. They ca also be used to speed up the process when conditions allow for a faster cycle time.

PLC Control
The machine will be controlled by a PLC with ladder logic programming. 12-volt Input-output modules will control machine functions through valves and sensors. Servo motion control runs through an SERCOS RING fiber optic communication block to control speed and location. An Ethernet module is used to communicate between the PLC and camera data. Data storage can be retrieved through small touch screen panels that are also used for operator interface
CYCLE TIME: 20 cycles per minute producing 40 assemblies per minute