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University of South Carolina 1Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
The Implementation of Robotic Automation for Syringe Filling Processes
John Cutler, Perry Diamond, Wyatt Jones, Jorden Krueger, Jackson PayneDr. Noble Anumbe, Dr. Ramy Harik, Jay Henderson, Kaishu Xia
University of South CarolinaMay 31, 2019
For further information: [email protected]
University of South Carolina 2Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
USC Team
Sr. Design Team Members: • John Cutler• Perry Diamond• Wyatt Jones• Jorden Krueger• Jackson Payne
Faculty Advisor: Ramy Harik
Scientific Support: Kaishu Xia
Office of Academic Engagement: • Jay Henderson• Noble Anumbe
Team Members
University of South Carolina 3Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Outline
I. Design Parameters
II. Simulation of Process
III. Equipment and Components
University of South Carolina 4Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Design ParametersSection I
University of South Carolina 5Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Design Parameters
Automation Responsibilities:
Operators two and three will be fully automated.
▪ Syringe Filling▪ Pump Actuation▪ Syringe Capping▪ Syringe Dispensing
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University of South Carolina 6Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Design Parameters
Sterilization Parameters:
▪ Opening of syringe packaging must take place within the ISO 5 hooded environment▪ Syringe tip must remain within the laminar flow at all times (preferably perpendicular
to the wall of airflow)▪ The process must take place at a depth of 6 inches from the front of the hooded
environment and six inches from the back of the hood▪ Once capped, the syringe may be removed from the ISO 5 environment
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University of South Carolina 7Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Design Parameters
Design Goals:
▪ Application of a singular Yaskawa Motoman GP8 ▪ Application of a singular fluid pumping device▪ 240 syringes per hour or 4 syringes per minute▪ Positioning of unboxed syringes for introduction into the automated process
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University of South Carolina 8Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Design Parameters
Application of Nephron Operators:
▪ Two operators will be expected to interact with the process by setting up the pump, loading syringes, loading caps, and conducting calibrations as needed
▪ One additional operator will be expected to perform quality checks of the capped syringes being dispensed from the storage container
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University of South Carolina 9Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Process SimulateSection II
University of South Carolina 10Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Process Simulate
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University of South Carolina 11Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Process Simulate: Advantages
▪ Prior to the start of production, optimization of the assembly process can result in a more accurate and efficient manufacturing plan. By utilizing assembly simulation to verify all process operation steps, the team can achieve:▪ Improved time-to-volume
production▪ Reduction in overall planning time▪ Shortened production setup time▪ Faster overall ramp up and delivery
timeline▪ Greater control over dependent
variables which decreases potential for contamination
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Simulation Panel
University of South Carolina 12Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment and ComponentsSection III
University of South Carolina 13Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment: Essential Manufacturing Materials
Syringes:
▪ 10 mL
503b Drugs:
▪ Multiple assortment of drug types▪ Different properties
Caps:
▪ Screw on type▪ 270 degrees of rotation for full seal▪ Universal across syringe sizes
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10 mL syringe with cap
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University of South Carolina 14Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment: Robotics
Yaskawa Motoman GP8:
▪ High speed, compact 6 axis robot ▪ 727 mm horizontal reach ▪ Small mounting footprint▪ User friendly interface/programming▪ Jog to teach capabilities
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Yaskawa GP8
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University of South Carolina 15Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment: Gripper
OnRobot RG2 Collaborative Gripper: ▪ Adjustable gripping stroke from 0 mm to 110
mm (4.3 inches)▪ Adjustable gripping force from 3 N to 40 N▪ Infinite rotation – cable connection turns with
gripper▪ Out of the box compatibility with Yaskawa
Robotics ▪ Fail safe, retains gripping force if power is cut ▪ Customizable Fingertips (rollers to facilitate
rotation)
Source: OnRobot.com
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Mounting of RG2
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University of South Carolina 16Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment: Gripper
Schunk EGP
▪ Electric 2-finger parallel gripper ▪ Compact dimensions
(L= 64 mm, W= 35 mm)▪ Designed for clean environments▪ 10 mm Stroke per jaw ▪ Max gripping force of 300 N
Schunk EGP
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Source: schunk.com
University of South Carolina 17Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment: Baxter 5300 Repeater Pump
Pump Currently in use at Nephron:▪ Max flow rate 13.5 mL/sec (water) ▪ Accuracy of +/- 1% over 2mL ▪ Peristaltic pump
▪ Liquid remains sterile ▪ Inaccuracies overtime
Actuation is currently a pneumatic and manually engaged bellow
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Depiction of peristaltic pump functions
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University of South Carolina 18Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment: Masterflex L/S Pump System
Overview:
▪ Stainless steel peristaltic pump▪ Remote I/O allows real-time control
of pump speed, flow rate, dispense volume
▪ Max flow rate is 1700 mL/min▪ Open-Head Sensor to prevent
improper setup▪ Masterflex Leak Detector will
shutdown the pump in less than 1 second in the event of a leak or tubing failure (accessory)
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Source: masterflex.com
Masterflex L/S Pump
University of South Carolina 19Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment and Components: Cap Package
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Model Drawing of Cap Package
University of South Carolina 20Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment and Components: Cap Array
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Model Drawing of Cap Array
University of South Carolina 21Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Equipment and Components: Syringe Dispenser
▪ We have begun to experiment with physical designs
▪ May we have a model of the syringe dispenser we saw during our tour of the plant?
▪ How many syringes is an optimal number to be able to store at one time in the slide?
▪ Can the syringes roll without disrupting the integrity of the seal?
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University of South Carolina 22Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Project Phases▪ Inception:
▪ Executive kick-off▪ Develop automation strategy road-map to prioritize schedule
▪ Planning:▪ Identify and document current manual process▪ Develop and critique conceptual processes
▪ Design and build:▪ Identify, produce, and install all hardware and controlled devices▪ Design finalized process
▪ Testing:▪ Perform unit testing▪ Evaluate the automated process
▪ Deployment and commissioning:▪ Confirm final baseline requirements and deliverables▪ Plan for full deployment and implementation
▪ Close-out and hand-over:▪ Develop a defect reporting procedure▪ Submit end stage report
University of South Carolina 23Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Goals Going Forward
June:▪ Pump selection
▪ Order needed equipment ▪ Gripper selection
▪ Decide on most suitable off the shelf solution ▪ Configure gripper for our purposes
▪ Further the depth of our Process Simulation ▪ Cap array finalization▪ Move into permanent McNair location
July:▪ Finalize design of syringe dispenser
▪ Number of syringes per fill▪ Most efficient dispensing angle
▪ Base design▪ Shelf concept▪ Fixture concept
University of South Carolina 24Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
Q&A
▪ Open discussion
University of South Carolina 25Nephron Capstone Project Cutler, Diamond, Jones, Krueger, Payne
The Implementation of Robotic Automation for Syringe Filling Processes
John Cutler, Perry Diamond, Wyatt Jones, Jorden Krueger, Jackson PayneDr. Noble Anumbe, Dr. Ramy Harik, Jay Henderson, Kaishu Xia
University of South CarolinaMay 31, 2019
