The Right Mix of Products for Recipe-Driven Machine Change Over

The filling of medical vials requires flexible automation equipment that can adapt to different vial sizes, colors and capping types. People are often deployed to make those equipment changes, which is also known as a recipe change. But by nature, people are inconsistent, and that inconsistency will cause errors and delay during change over.

Here’s a simple recipe to deliver consistency through operator-guided/verified recipe change. The following ingredients provide a solid recipe-driven change over:

Incoming Components: Barcode

Fixed mount and hand-held barcode scanners at the point-of-loading ensure correct parts are loaded.

Change Parts: RFID

Any machine part that must be replaced during a changeover can have a simple RFID tag installed. A read head reads the tag in ensure it’s the correct part.

Feed Systems: Position Measurement

Some feed systems require only millimeters of adjustment. Position sensor ensure the feed system is set to the correct recipe and is ready to run.

Conveyors Size Change: Rotary Position Indicator

Guide rails and larger sections are adjusted with the use of hand cranks. Digital position indicators show the intended position based on the recipes. The operators adjust to the desired position and then acknowledgment is sent to the control system.

Vial Detection: Array Sensor

Sensor arrays can capture more information, even with the vial variations. In addition to vial presence detection, the size of the vial and stopper/cap is verified as well. No physical changes are required. The recipe will dictate the sensor values required for the vial type.

Final Inspection: Vision

For label placement and defect detection, vision is the go-to product. The recipe will call up the label parameters to be verified.

Traceability: Vision

Often used in conjunction with final inspection, traceability requires capturing the barcode data from the final vials. There are often multiple 1D and 2D barcodes that must be read. A powerful vision system with a larger field of view is ideal for the changing recipes.

All of these ingredients are best when tied together with IO-Link. This ensures easy implantation with class-leading products. With all these ingredients, it has never been easier to implement operator-guided/verified size change.

Using MicroSpot LEDs for Precise Evaluations in Life Science

Handling microfluidics and evaluating samples based on light is a precise science. And that precision comes from the light source, not the actual detection method. But too many times we see standard LEDs being used in these sensing and evaluation applications. Standard LEDs are typically developed for lighting and illumination applications and require too many ancillary components to achieve a minimum level of acceptability. Fortunately, there is an alternate technology.

First, let’s look at a standard LED. Figure 1 shows a typical red LED. You can see the light emission surface is cluttered with the anode pad (square in the middle) and its bond wire. These elements are fine for applications like long-range sensing, lighting and indications, but for precise, up-close applications they cause disturbances.

Figure 1: Typical red LED showing the intrusion of the anode and bond wire into the light emission

Most notable is the square hole in the middle of the emission pattern. There are two typical methods to reduce the effect of the hole: lensing and apertures. An aperture essentially restricts the emitted light to a corner of the die, substantially reducing the light energy causing difficulties with low-contrast detections. Using a lens only will maintain the light energy, but the beam will have a fixed focused point that is not acceptable for many applications. But even the bond wire produces reflections and causes spurious emissions. These cannot be tolerated with microfluidics as adjacent channels will become involved in the measurement. An additional aperture is typically used to suppress the spurious emissions.

Fortunately, there is an alternative with MicroSpot LEDs. Basically, the anode and emission areas are inverted as shown in the Figure 2 comparison.

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Figure 2: Comparison of the typical LED with the MicroSpot’s clean, powerful and collimated emission

This eliminates the need for the anode and bond wire to interfere with the emitted light. This produces a clean, powerful and collimated emission that will produce consistent results without additional components. This level of beam control is typically reserved for lasers. However, lasers also require more components, are much larger and cost more. The MicroSpot LED is the best choice for demanding life science applications.

Try the MicroSpot for yourself in select Balluff MICROmote miniature photoelectric sensors.

Learn more at www.balluff.com.