GB2625078A - Improvements to processing apparatus - Google Patents

Abstract

Processing apparatus 10 for use in material transfer comprises a robotic material transfer system comprising one or more robots with a robotic arm 12 for manipulating a transfer container 20, the robotic arm 12 having grabber assembly 14 with two gripping arms (100, 102 figure 2) at least one opposing gripping arm (100, 102 figure 2) is moveably mounted such that it can move towards the other to grip or release a transfer container 20, a sensor (500, 502 figure 2) for determining the position of one or more of the gripping arms (100, 102 figure 2) relative to a transfer container 20, at least one power source or motor (106 figure 2) for displacing the at least one moveably mounted gripping arm (100, 102 figure 2) and optionally, one or more real-time imaging devices for providing real-time visual monitoring of the one or more robots and the gripping arms (100, 102 figure 2) comprise one member of mating means to facilitate mating with a transfer container 20. The mating means may comprise elongate rectangular recesses (210, 212 figure 2) on the gripping arms (100, 102 figure 2) that are complementarily shaped to elongate rectangular protrusions that are disposed on the side of the transfer container 20. The robotic material transfer system may be used for feeding material to a comminuting device 18 or collecting material from an outlet of the comminuting device 18.

Description

Improvements to Processing Apparatus The present invention relates to processing apparatus and methods using such processing apparatus for use in material transfer during manufacturing processes. In particular, the present invention relates to such apparatus and methods to improve operator and/or product protection when compared to a traditional clean room or an isolation and/or containment system employed for operators.

The transfer of material from one vessel to another poses a number of problems particularly concerning maintenance of the processing environment to prevent the contamination of the material being transferred, the vessels themselves and the surrounding environment in which operators of such transfer devices may be located to effect the transfer of material.

The maintenance of sterility is of fundamental concern in many manufacturing processes, to safeguard against contamination of products being manufactured in the process. Exemplary industries using aseptic production in a traditional manner or in isolation and/or containment facilities include pharmaceutical, medical device, biotechnological and food industries.

Particular difficulty can arise where material for use in manufacture is required to be transferred from one sterile enclosure to another.

Developments in containment facilities led to the introduction of direct and indirect transfer devices. An example of a direct transfer device is a split butterfly valve system and an example of an indirect transfer device includes mating ports, otherwise known as rapid transfer (RTP) ports. Both transfer devices enable material to be transferred from one area to the other without contaminating the material or the surrounding environment.

Known transfer systems are often large or cumbersome for operators to manipulate, often requiring complex lifting equipment which is difficult to manoeuvre and operate in processing environments.

The processing environment can also pose a health risk to operators owing to potential hazards to health from the material being transferred and/or potential contamination of the transfer material from the operator.

With new medicines being increasingly highly potent, operator safety is of paramount importance. Current practise is to use containment valves or barriers for the transfer of highly potent Active Ingredients. However, this method still involves manual handling with the operator working closely to the transfer point and at risk of exposure. Improvements need to be made to protect manufacturing operatives.

Other complexities in this industry relate to process efficiency with the aim of achieving continuous manufacturing solutions.

In accordance with the present invention there is provided apparatus for use in material transfer comprising a robotic material transfer system comprising: one or more robots having a robotic arm for manipulating a transfer container; a grabber assembly disposed on the robotic arm having two opposing gripping arms, at least one opposing gripping arm is moveably mounted such that it can move towards the other to grip or release a transfer container; a sensor for determining the position of one or more of the gripping arms relative to a transfer container; at least one power source for displacing the at least one moveably mounted gripping arm; and optionally, one or more real-time imaging devices for providing real-time visual monitoring of the one or more surgical robots.

Robotic materials handling offers an agile solution that suits the vast majority of the current market, potentially dramatically accelerating adoption of continuous manufacturing at a significantly lower risk and cost.

The present invention compliments current manufacturing methods such that pharmaceutical production, for example, can be adapted with minimal change to existing processes and product licenses, but significantly improving efficiency and reducing manufacturing costs.

Using robotic technology to automate a 'continuous materials handling flow' presents an opportunity to gain the greater efficiency needed in drug manufacturing whilst allowing existing processes to be maintained. Robots will allow the operator to be removed from the manufacturing environment, thus improving operator safety The transfer container is preferably manufactured from one or more lightweight material. Advantageously, the transfer material is manufactured from plastics. More advantageously, the transfer container is manufactured from Polyethylene (or similar material).

Using a lightweight material for the transfer container reduces the load on the robotic arm enabling more complicated movements to be achieved and improved manipulation of the container.

The transfer container may be advantageously (1) light enough to be handled by a robot and (2) are low cost enough to allow the many hundreds that would be needed for a continuous manufacturing methodology.

The transfer container and/or gripping arms may comprise gripping means.

The transfer container and gripping arms may comprise means for mating. The means for mating preferably comprise complementarily shaped features disposed on the container and the gripping arm. The complimentarily shaped features may provide for improved grip. The complementarily shaped features may comprise a recess and complementarily shaped protrusion. The recess and protrusion may be shaped to enable the container to be keyed with the gripping arms to prevent rotation of the container between the gripping arms when gripped.

The apparatus may further comprise other processing equipment associated with pharmaceutical, medical device, biotechnological and food industries manufacture. The environment, may advantageously be aseptic.

In accordance with a further aspect of the present invention, there is provided apparatus and at least one transfer container as described hereinabove.

In accordance with a further aspect of the present invention, there is provided a method for material transfer comprising the use of apparatus as described hereinabove.

The present invention may offer one or more of the following advantages and features: o Method of semi-automating the powder handling and transferring process to allow for reduced human interaction, improved efficiencies and repeatable improved performance and quality.

o Doing so by producing a system that allows for removal of operators and direct replacement with robotic mechanisms for bottle moving/blending/transport and also containment valve operation o Reduced human interaction allows for improved safety for individuals and reduces likelihood of human error o Integrating a robotic arm with an increased range of movement and operation requires lighter load, which can be offered due to the development of individual aspects within the solution o The method of gripping and design of solution elements allow for multi-axis rotation whereas some traditional methods can only be gripped/rotated within a single axis * loT and live feedback to maximise efficiency/safety/repeatability across multiple process steps o The gripper is complimentary to the bottle shape and design and gives direct feedback to the robot and system regarding position and state The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Fig. la -c shows a schematic of apparatus in accordance with the present invention for dry granulation; Figs. 2 and 3 show gripping arms in accordance with the present invention including internal features; and Fig. 4 shows the gripping arm of Figs. 2 and 3 with protective cover over the internal features.

Fig. 1 shows process apparatus 10 comprises a robotic arm 12 with grabber assembly 14, a container 16 and comminuting device 18. Grabber assembly 14 has grabbed and retains a transfer container 20 containing material to be transferred to other process equipment, here the comminuting device 18.

Fig. 1 a) shows pre-blending of the contents of the container 16, Fig. 1 b) shows feeding to the comminuting device 18 with blended powder and Fig. 1 c) shows collecting the processed granules from the machine outlet.

The process apparatus maximises the handling operations and continuously feeding and collecting materials to and from the process, reduces blending times with an improved blend pattern afforded by the multi-axis movements of the robotic arm and removes the operator from the process room, improving safety and hygiene.

The transfer container 20 is manipulated by the robotic arm 12 into the desired orientation. The robotic arm is capable of manipulating the grabber assembly along an X-axis assembly for positioning the grabber along an X-axis, a Y-axis assembly for positioning the grabber along a Y-axis, a Z-axis assembly for positioning the grabber along a Z-axis and, a pivotal assembly for positioning the grabber at an angle [theta].

Figs. 2 to 4 show the grabber assembly 16 comprising a housing 90 having rectangular cross section and two gripping arms 100, 102 that depend substantially perpendicularly therefrom. One gripping arm 100 is fixed relative to the housing and the other 102 is moveably mounted thereto.

Gripping arm 102 is mounted to a moveable platform 104 and is moveable between a gripping configuration in which the gripping arm 102 grips the transfer container and a released configuration in which the gripping arm 102 does not grip the transfer container.

The gripping arm 102 is powered by a motor 106 that is capable of moving the gripping arm 102 between its configurations. Fig. 4 shows the gripping arm 102 in its released configuration whereby the grabber assembly does not mate with a container.

The inner faces 200, 202 of the gripping arms 100, 102 respectively have elongate rectangular recesses 210, 212 that are complementarily shaped to elongate rectangular protrusions that are disposed on the side of the transfer container 20.

The recesses 210, 212 are shaped to receive the protrusions to key the transfer container in the grabber assembly in the gripping configuration and mate therewith to allow manipulation of the transfer container.

The free ends 220, 222 of the gripping arms 100, 102, respectively, have a chamfered edge to facilitate easier initial engagement of the gripping arms with the transfer container and to facilitate guiding of the container into the desired position between the gripping arms 100, 102. Similarly, the upper and lower internal edges 300, 400 and 302, 402 of each gripping arm are also chamfered to achieve the same effect.

Each gripping arm has a sensor SOO, 502 for sending when a transfer container is received in the recesses and correctly mated to facilitate manipulation.

Claims (14)

1. Claims 1.Apparatus for use in material transfer comprising a robotic material transfer system comprising: one or more robots having a robotic arm for manipulating a transfer container; a grabber assembly disposed on the robotic arm having two opposing gripping arms, at least one opposing gripping arm is moveably mounted such that it can move towards the other to grip or release a transfer container; a sensor for determining the position of one or more of the gripping arms relative to a transfer container; at least one power source for displacing the at least one moveably mounted gripping arm; and optionally, one or more real-time imaging devices for providing real-time visual monitoring of the one or more surgical robots, wherein, the gripping arms comprise one member of mating means to facilitate mating with a transfer container.
2. 2. Apparatus as claimed in claim 1 wherein the at least one moveable gripping arm is capable of translational movement relative to the other gripping arm.
3. 3. Apparatus as claimed in claim 2 wherein both gripping arms are capable of movement relative to the one other.
4. 4. Apparatus as claimed in claim 3 wherein both gripping arms are capable of translational movement relative to one another.
5. 5. Apparatus as claimed in any one of the previous claims wherein the movement of the at least one gripping arm is via a power unit disposed in the grabber assembly.
6. 6. Apparatus as claimed in any one of the previous claims wherein the at least one member of mating means comprises at least one male member or at least one a female member.
7. 7.Apparatus as claimed in claim 6 wherein the mating means comprises two male members and two female members.
8. 8. Apparatus as claimed in claim 7 wherein the male member is disposed on the transfer container and the female member on the gripping arms.
9. 9.Apparatus as claimed in claim 6, 7 or 8 wherein the male member is an elongate rectangular protrusion and the female member is a complementarily shaped recess.
10. 10.Apparatus as claimed in any one of the previous claims wherein the sensor detects whether the grabber assembly has gripped or released the transfer container.
11. 11. Apparatus as claimed in claim 10 wherein the sensor is a pressure sensor.
12. 12. A transfer system comprising an apparatus as claimed in any one of claims 1 to 11 apparatus and at least one transfer container.
13. 13. A transfer system as claimed in claim 12 wherein the gripping arms each have a female member of mating means and the transfer container has two male members of mating means.
14. 14. A method for material transfer comprising the use of a transfer system as claimed in claim 12 or 13.