Assembly line having carrier for transporting components and method of operation thereof

An assembly line having a carrier for transporting components which is structured and dimensioned for receiving components of two different devices, so that the assembly line can be switched from assembling one device to assembling the other device without changing or altering the series of carriers on the assembly line, and a method of operating the assembly line.

The present description relates to a carrier for transporting components on an assembly line that is structured and dimensioned for receiving components of two different devices, so that the assembly line can be switched from assembling one device to assembling the other device without changing or altering the series of carriers on the assembly line.

BACKGROUND

In some instances, a single assembly line can be used for assembling different devices whose respective components are similar to each other but have different dimensions and shapes. Switching that assembly line from assembling one device to assembling another can be a time-consuming evolution that idles production and is inefficient. One example is an assembly line that assembles nasal spray devices. Such devices may comprise three components that are assembled together: a filled vial, a vial holder into which the filled vial is inserted, and an actuator grip that is inserted over and surrounds at least part of the vial holder and filled vial. Such devices come in at least two sizes containing different amounts of nasal spray. Switching an assembly line from assembling one size to assembling another is time consuming and inefficient, considering that producing of such devices is measured in hundreds of doses per minute.

SUMMARY

A method of operating an assembly line having assembly stations and a plurality of carriers for transporting components of a vial-based device between the assembly stations is provided. Each carrier comprises first and second device receptacles, the first device receptacle being structured and dimensioned differently than the second device receptacle, the first device receptacle being adapted for receiving components of a first vial-based device, and the second device receptacle being adapted for receiving components of a second vial-based device. The carrier is further adapted for attachment to a car that travels along the assembly line, the plurality of carriers being arranged in a series of cars. The method comprises the steps of assembling a plurality of either one of the first and second vial-based devices; switching the assembly line to assemble the other one of the first and second vial-based devices without changing or altering the series of the carriers on the assembly line; and assembling a plurality of the other one of the first and second vial-based devices.

The first device receptacle may comprise a first vial holder support for receiving a first vial holder of the first vial-based device. The first device receptacle may comprise a first actuator grip support for receiving a first actuator grip of the first vial-based device.

In another example, the first device receptacle comprises a cylindrical tube, having a top that is open wide enough for receipt of a first actuator grip of the first vial-based device, having a diameter and a length structured to support the first actuator grip, and having a bottom with a circular opening that is wide enough for at least part of a first vial holder of the first vial-based device to pass through the opening but narrow enough to prevent the first actuator grip from passing through the opening; and a bottom support located underneath the bottom of the cylindrical tube, and structured to support the at least part of the first vial holder passing through the opening.

In some examples, when the method is in operation, the at least part of the first vial holder passes through the cylindrical tube and through the opening, and is supported by the bottom support and by the bottom of the cylindrical tube; a first filled vial of the first vial-based device is inserted into the first vial holder after the at least part of the first vial holder has passed through the cylindrical tube and through the opening and the at least part of the first vial holder is supported by the bottom support and by the bottom of the cylindrical tube; and the first actuator grip is inserted over and surrounds at least part of the first vial holder and the first filled vial, and is supported by the cylindrical tube, after the first filled vial has been inserted into the first vial holder. The method cylindrical tube may be freely rotatable about its vertical axis to any angular orientation within the first device receptacle.

The second device receptacle may comprise a second vial holder support for receiving a second vial holder of the second vial-based device. The second device receptacle may comprise a second actuator grip support for receiving a second actuator grip of the second vial-based device.

The second device receptacle may comprise: a top support having a length and a width structured to allow a second actuator grip of the second vial-based device to fit over and to be supported by the top support, and having a circular opening that is wide enough for at least part of a second vial holder of the second vial-based device to pass through the opening; and a bottom support located underneath the top support, and structured to support the at least part of the second vial holder passing through the opening.

In some examples of when the method is in operation, the at least part of the second vial holder passes through the opening, and is supported by the bottom support and by the top support; a second filled vial of the second vial-based device is inserted into the second vial holder after the at least part of the second vial holder has passed through the opening and the at least part of the second vial holder is supported by the bottom support and by the top support; and the second actuator grip is inserted over and surrounds the top support and at least part of the second vial holder and the filled second vial, and is supported by the top support, after the second filled vial has been inserted into the second vial holder.

In some embodiments, an assembly line for assembling first vial-based devices and second vial-based devices, the first vial-based devices being dimensioned differently than the second vial-based devices are provided. The assembly line comprises a series of the carriers, a series of the cars, the series of the carriers being attached to the series of the cars, respectively; a series of the assembly stations; and a conveyor system for transporting the cars between the assembly stations.

Each carrier comprises: first and second device receptacles, the first device receptacle being adapted for receiving components of the first vial-based device, and the second device receptacle being adapted for receiving components of the second vial-based device. The carrier is adapted for attachment to a car that travels along the assembly line. When a series of the carriers is attached to a series of the cars, respectively, the assembly line can be switched from assembling either one of the first and second vial-based devices to assembling the other one of the first and second vial-based devices without changing or altering the series of the carriers on the assembly line.

The assembly line may further comprise: a vial holder insertion station for inserting a first or a second vial holder into each of the carriers; a filled vial insertion station for inserting a first or a second filled vial into the vial holder that has been inserted into each of the carriers; and an actuator grip insertion station for inserting a first or a second actuator grip over and surrounding at least part of the vial holder and filled vial that has been inserted into each of the carriers. The components of the first vial-based device comprise the first vial holder, the first filled vial, and the first actuator grip. The components of the second vial-based device comprise the second vial holder, the second filled vial, and the second actuator grip. The series of assembly stations comprise the vial holder insertion station, the filled vial insertion station, and the actuator grip insertion station.

The series of assembly stations may further comprise a packaging directing station for directing the assembled first and the second vial-based devices to a selected station for packaging.

The assembly line may further comprise a pull-test mechanism that has a first part for gripping an actuator grip of at least one of the first and second vial-based devices after assembled, and a second part for gripping a vial holder of the least one of the first and second vial-based devices after assembled, the first and second parts being connected by a spring and being operated by temporarily pulling them apart to a specified tension to test whether the actuator grip is secured to the vial holder.

The assembly line may further comprise: a series of individual mover pucks; each individual mover puck being a holder into which either the assembled first vial-based device or the assembled second vial-based device is placed for transport along a conveyor belt; where each individual mover puck being structured and dimensioned to accommodate either the assembled first vial-based device or the assembled second vial-based device, whichever is required.

The assembly line may further comprise a labeling station, wherein the labeling station comprises at least a first labeling module capable of applying wrap-around labels when assembling at least one of the first and second vial based devices and applying spot labels when assembling the other of the first and second vial based devices. The labeling station may further comprise a second labeling module capable of applying spot labels when assembling the other of the first and second vial-based devices.

DETAILED DESCRIPTION

FIG.1illustrates exemplary components of a Bi-Dose device: vial holder101, filled vial103, and actuator grip105; and of the Unit-Dose device: vial holder111, filled vial113, and actuator grip115. Actuator grip105may be modified to include additional area for engagement with a user's fingers during use. Advantageously, an assembly line using the carriers described and claimed in the present application can assemble 200 units per minute, without lengthy downtimes for switching from assembling a Bi-Dose device to assembling a Unit-Dose device and vice versa.

FIGS.2-8show perspective, front, rear, right side, left side, top and bottom views, respectively, of an example of a carrier200for transporting components of a vial-based device between assembly stations on an assembly line. The carrier200is adapted for attachment to a car230designed to be transported along an assembly line300(discussed below). For example, a carrier200can be bolted to a car230through openings220as seen inFIGS.2-4. An embodiment of a carrier200attached to a car230is illustrated inFIG.9.

The illustrated carrier200includes a receptacle seen on the left side ofFIG.3, for example, that is structured and dimensioned for receiving components of the Bi-Dose device illustrated inFIG.1. Carrier200includes a receptacle seen on the right side ofFIG.3, for example, that is structured and dimensioned for receiving components of the Unit-Dose device illustrated inFIG.1.

The receptacle seen on the left side ofFIG.3includes a sleeve201surrounding a cylindrical tube having a top202that is open wide enough for receipt of an actuator grip105, having a diameter and a length structured to support an actuator grip105, and having a bottom203with a circular opening204that is wide enough for at least part of a vial holder101to pass through the opening204but narrow enough to prevent an actuator grip105from passing through the opening204. The receptacle seen on the left side ofFIG.3also includes a bottom support206, located underneath the bottom203of the sleeve201, that is structured to support at least part of a vial holder101passing through the opening204.

As a result, at least part of a vial holder101can pass through the cylindrical tube and through the opening204, and can be supported by the bottom support206and by the bottom203of the cylindrical tube. Then, a filled vial103can be inserted into the vial holder101. Then, an actuator grip105can be inserted over and can surround at least part of the vial holder101and the filled vial103, and can be supported by the cylindrical tube.

FIGS.10A-10Dillustrate an example of the sequential insertion of a vial holder101(FIG.10A), insertion of a filled vial103(FIG.10B), insertion of an actuator grip105(FIG.10C), and an assembled Bi-Dose device in the receptacle seen on the left side ofFIG.10D.

In the illustrated embodiment, the combination of the bottom support206and the bottom203of the cylindrical tube constitute a vial holder support, and the cylindrical tube constitutes an actuator grip support. Many embodiments can be devised, as long as they are structured and dimensioned for receiving and supporting components of a device being assembled along an assembly line.

In some embodiments, the cylindrical tube is freely rotatable about its vertical axis to any angular orientation within the receptacle seen on the left side ofFIG.3. For example, it can rotate freely within sleeve201. For example, this ability to rotate facilitates the application of a wrap-around label to an assembled device. The label can be applied at one point, and then the device can be rotated 360° while applying pressure via a belt to ensure that the label adheres to the device.

The receptacle seen on the right side ofFIG.3includes a top support211having a length and a width structured to allow an actuator grip115to fit over and to be supported by the top support211, and having a circular opening212that is wide enough for at least part of a vial holder111to pass through the opening212. The receptacle seen on the right side ofFIG.3also includes a bottom support214, located underneath the top support211, and structured to support at least part of the vial holder111passing through the opening212.

As a result, at least part of a vial holder111can pass through the opening212, and can be supported by the bottom support214and by the top support211. Then, a filled vial113can be inserted into the vial holder111. Then, an actuator grip115can be inserted over and can surround the top support211and at least part of the vial holder111and the filled vial113, and can be supported by the top support211.

FIGS.11A-11Dillustrate an example of the sequential insertion of a vial holder111(FIG.11A), insertion of a filled vial113(FIG.11B), insertion of an actuator grip115(FIG.11C), and an assembled Unit-Dose device in the receptacle seen on the right side ofFIG.11D.

In the illustrated embodiment, the combination of the bottom support214and the top support211constitute a vial holder support, and the top support211constitutes an actuator grip support. Many embodiments can be devised, as long as they are structured and dimensioned for receiving and supporting components of a device being assembled along an assembly line.

FIG.12is a schematic representation of an exemplary assembly line300for assembling both the Bi-Dose and the Unit-Dose devices whose components are illustrated inFIG.1. A series of carriers200is attached to a series of cars230, respectively, forming a series of car/carriers such as those illustrated inFIG.9. The car/carriers are transported along a conveyor system302between a series of assembly stations including, for example, a vial holder insertion station304, a filled vial insertion station306, an actuator grip insertion station308, and a packaging directing station310.

In the illustrated example, vial holder feeder312is loaded with vial holders selected for the device being assembled, and sends the vial holders to vial holder insertion station304where a vial holder is inserted into the applicable receptacle of each carrier200. Filled vial feeder314is loaded with filled vials selected for the device being assembled, and sends the filled vials to filled vial insertion station306where a filled vial is inserted into the vial holder that has been inserted into each carrier200. Actuator grip feeder316is loaded with actuator grips selected for the device being assembled, and sends the actuator grips to actuator grip insertion station308where an actuated grip is inserted over and surrounds at least part of each vial holder/filled vial that has been inserted into each carrier200. Label feeder318is loaded with labels selected for the device being assembled, and sends the labels to packaging directing station310where a label is applied to each assembled device and the device is directed to a selected packaging station320A,320B, or320C, for example.

In some embodiments, the packaging directing station310comprises a labeling station having a plurality of labeling modules. In one example, the labeling station comprises a labeling module that is capable of applying wrap-around labels and spot labels. In the case of the Bi-Dose device, as set forth above, the receptacle allows for rotation of an assembled device to facilitate application of a wrap-around label. A first labeling module includes, for example, two servo-driven conveyor belts to rotate the Bi-Dose device at a speed synchronized with the carrier travel to apply a wrap-around label. For devices that are not amenable to rotation, front and back labels may be applied. In one example, a second labeling module is added. For example at the first labeling module, a first side label (e.g., back of the device) may be applied to a Unit Dose device, and at the second labeling module, a second side label (e.g., front) may be applied to a Unit Dose device. The labeling modules may include a laser to write data onto labels and a vision system to optically inspect labels before application to a device. In this way, different labeling requirements can be accomplished without change-over of any equipment on the assembly line.

Because each carrier200can be used in assembling either a Bi-Dose device or a Unit-Dose device in the described example, carriers200attached to cars230can be transported along conveyor system302without change or alteration when the assembly line is switched from assembling the Bi-Dose device to assembling the Unit-Dose device, and vice versa.

When switching from assembling one device to assembling the other, the applicable components and labels are fed in bulk to the vial holder feeder312, the filled vial feeder314, the actuator grip feeder316and the label feeder318, respectively. However, same carriers200continue to be transported along the conveyor system302.

In some embodiments, multiple carriers200move together from one assembly station304,306,308and310to the next. For example, each assembly station304,306,308and310can be designed to accommodate eight carriers200simultaneously. When the function of each of the assembly stations304,306,308and310is completed, all eight carriers200at each of the assembly stations304,306and308are transported to the next assembly station306,308and310, the empty carriers200at packaging directing station310move on, and a new set of eight empty carriers200arrive at vial holder insertion station304. In some embodiments, the conveyor system302uses electro-magnetic pulses to transport the cars230between the assembly stations304,306,308and310.

Various features specific to the devices being assembled are built into the assembly line300. For example, there can be quality control tests to confirm the integrity and operability of a component. In some embodiments, the assembly line300can include a pull-test mechanism330such as illustrated inFIG.13. The test mechanism330has a first part331for gripping an actuator grip115of at least the Unit-Dose devices after assembled, and a second part332for gripping a vial holder111of at least the Unit-Dose devices after assembled. The first and second parts331and332are connected by a spring and are operated by temporarily pulling them apart to a specified tension to test whether the actuator grip115is secured to the vial holder111. Typically, vial holder111has a snap ring112for retaining vial holder111within actuator grip115. The first part331has a cup for holding a top of actuator grip115, the second part332has two legs for holding vial holder111, and pull-test mechanism330detects whether the snap ring112has been damaged and is not performing its function.

The following are examples of some other features included in the assembly line300in some embodiments. For example, the assembly line300can include reference mechanisms to ensure the correct spacing of carriers200at the assembly stations304,306,308and310. There can be sensors to ensure that the carriers200are empty when they arrive at vial holder insertion station304. There can be pick-and-place A robots at each of the assembly stations304,306,308and310for accurate insertion of components into the applicable receptacle for the device being assembled, or for transfer of assembled devices from the receptacles to mover pucks340(discussed below).

The alternative packaging stations320A,320B, or320C, for example, accommodate not only the two different devices, but also allow for different types of packaging such as for individual devices or for different numbers of multiple devices, and allow for the use of different types of packaging materials. The packaging directing station310can be controlled to direct certain numbers of devices to the selected packaging stations320A,320B, and320C, for example.

FIG.14Ais an illustration of an exemplary mover puck340structured and dimensioned so that any individual mover puck340can accommodate either an assembled Bi-Dose device or an assembled Unit-Dose device, whichever is required.FIG.14Billustrates an assembled Bi-Dose device placed in a mover puck340.FIG.14Cillustrates an assembled Unit-Dose device placed in a mover puck340. The mover pucks340are holders into which an assembled device can be placed for transport along a conveyor belt. For example, individual assembled devices that are removed from carriers200at packaging directing station310can be placed in respective mover pucks340for transport to a selected packaging station320A,320B, or320C, for example.

It will be understood that the disclosed carrier and assembly line device can be modified without departing from the teachings of the invention. Accordingly, the scope of the invention is to be limited only as necessitated by the accompanying claims.