WO2006043020A1

WO2006043020A1 - Conveying apparatus

Info

Publication number: WO2006043020A1
Application number: PCT/GB2005/003684
Authority: WO
Inventors: Franciscus Antonius Damen; Harms Van Der Velden
Original assignee: The Boc Group Plc
Priority date: 2004-10-18
Filing date: 2005-09-23
Publication date: 2006-04-27
Also published as: CN101044073A; EP1809554A1; GB0423101D0; JP2008516866A

Abstract

A conveying system comprises a rotating surface (18); a first conveyor for conveying upright articles (16) towards a transfer device for transferring articles from the first conveyor (12) to the rotating surface (18), the transfer device comprising a guide surface (24) moving at a substantially constant speed towards the rotating surface and extending obliquely over the first conveyor (12) and the rotating surface (18); a second conveyor (66); and a curved guide surface (38) for guiding articles transferred to the rotating surface (18) towards the outer periphery thereof for subsequent transfer to the second conveyer.

Description

CONVEYING APPARATUS

The invention relates to a conveying system for conveying articles. In one example, the invention provides a system for receiving a multi-row stream of sterilised containers or vials from a freeze dryer or sterilisation tunnel, and arranging the vials in a single row for feeding on to a conveyor.

Freeze drying is a process that removes from a product water in the form of ice. In the freeze drying process, the product is frozen and, under vacuum, the ice sublimes and the vapour flows towards a condenser. Freeze drying is particularly useful in the pharmaceutical industry, as the integrity of the products is preserved during the freeze drying process and product stability can be guaranteed over relatively long periods of time.

Freeze dryers typically incorporate a pressure vessel having a freeze drying chamber for receiving a plurality of containers or vials containing the product to be freeze dried. Access to the chamber for automated loading and removal of vials is through a rectangular opening, or slot, formed in a wall or in the main door of the chamber. A moveable slot door closes the slot, and forms, with the chamber, a vacuum seal around the slot. To enable vials to be inserted into the chamber, the slot door is raised, enabling a loading mechanism provided opposite the slot door to push vials from a conveyor on to a shelf of the chamber. The vials may be loaded on to a shelf in a number of different ways, for example, a number of rows at a time, or a complete shelf full at a time. Once loading has been completed, the loading mechanism is withdrawn and the slot door is closed to enable the contents of the vials to be freeze dried. The vials can be subsequently removed from the chamber, typically in the same manner as they were loaded into the chamber, using an unloading mechanism, which moves the rows of sterilised vials back on to the conveyor for subsequent transfer to a capping machine or the like for sealing the sterilised vials. Capping machines generally require the vials to be conveyed therethrough in a single row, and so it is necessary to convert the multi- row stream of vials received from the freeze dryer into a single row. It is known to provide a funnelling arrangement that receives the sterile vials from the conveyor and channels the vials into a single row. The sterile vials are moved through the funnelling arrangement by virtue of the forces exerted from behind by vials being conveyed into the funnelling arrangement by the conveyor. Sterile vials tend to exhibit strong sticking and friction effects when pressed against other sterile vials, and this can prevent a smooth transition into a single row of vials. Whilst a vibrating plate could be used to separate the individual vials within the funnelling arrangement, such plates tend to require complicated set up and tuning procedures. Furthermore, this solution can lead to scratching of the vials (as sterile glass vials tend to be extremely abrasive) and the generation of particulates, and sometimes even vial breakage.

It is an aim of at least the preferred embodiment of the present invention to provide a conveying system that can convert a multi-row stream of sterile vials into a single row whilst minimising the risks of blockage and vial damage.

In a first aspect, the present invention provides a conveying system comprising a rotating surface; a conveyor for conveying upright articles towards a transfer device for transferring articles from the conveyor to the rotating surface, the transfer device comprising a guide surface moving at a substantially constant speed towards the rotating surface and extending obliquely over the conveyor and the rotating surface; and a curved guide surface for guiding articles transferred to the rotating surface towards the outer periphery thereof for subsequent removal therefrom.

The curved guide surface serves to separate out the articles, for example, sterilised vials, as they are conveyed by the rotating surface. As the radius of the curved guide surface increases, the tangential speed of the vials travelling along the curved guide surface also increases. This in turn increases the spacing between the vials, allowing them to adopt a single row formation. Pharmaceutical containers such as vials and ampoules tend to have relatively high height to diameter ratios, which makes them susceptible to toppling as they are conveyed through the conveying system. By providing a moving guide surface for transferring the vials from the conveyor to the rotating surface, the speed of the vials as they move through the conveying system can be accurately controlled. By controlling the relative speed of the moving guide surface and the position of the moving guide surface relative to the conveyor and the rotating surface, the vials can be accelerated gradually through the transfer device and delivered to the rotating surface such that there is no sudden change in acceleration as the vials leave the transfer device. This can reduce greatly the likelihood of the vials toppling as they are transferred to the rotating table, and thus can enable the vials to be conveyed through the system at a relatively high speed, for example, up to 600 vials per minute.

Furthermore, by providing a moving guide surface for transferring the vials from the conveyor to the rotating surface, the vials can be transported through the conveyor system directly by actuating devices, namely the conveyor, the moving guide surface and the rotating surface, in contrast to the prior art where the vials are pushed through a funnelling arrangements by the preceding vials. This has been found to inhibit blocking of the conveyor system by the vials.

The conveyor is preferably provided by a single linear conveyor, or by a plurality of linear conveyors located side by side. The conveyor(s) are preferably located to one side of the rotating surface, more preferably such that one of the conveyors is tangential to the rotating surface. By avoiding any "dead plates", that is, stationary surfaces between the conveyor and the rotating surface, the transfer of the vials between the conveyor and the rotating surface can be as smooth as possible, and, by turning off the actuating devices in sequence, the system can be emptied of vials completely (as there are no dead plates on which vials remain when the system is switched off). - A -

The transfer device preferably comprises a second guide surface spaced from the moving guide surface to define a channel for articles transferred to the rotating surface. In the preferred embodiments, the second guide surface is stationary, and so can be conveniently continuous with the curved guide surface. Alternatively, the second guide surface may also be moving at the same speed as the first-mentioned moving guide surface. The guide surfaces are preferably substantially parallel to each other, although one surface could be at an acute angle to the other if so desired. Advantageously, the transfer device may comprise a third, moving guide surface located adjacent the mouth of the channel and moving against the direction of movement of the articles into the channel. This can serve to separate the vials as they enter the channel and thus reduce both the pressure exerted on the vials and the risk of blockage.

The curved surface preferably extends outwards from the transfer device in a direction of rotation of the rotating surface towards the periphery of the rotating surface. The precise shape adopted by the curved surface depends, inter alia, on the diameter of the vials and the diameter of the rotating surface. For example, the curved surface may simply extend spirally outwards, or may have a more complex shape. In one preferred embodiment, the curved surface comprises a first convex portion for receiving articles from the transfer device, a second, convex portion, and a third, concave portion located between the first and second portions. The transition between the concave portion and the second convex portion can serve to promote separation of the vials conveyed by the rotating surface. Thus, in a second aspect the present invention provides a conveying system comprising a rotating surface; a conveyor for conveying upright articles to the rotating surface; and a curved guide surface for guiding articles received by the rotating surface towards the outer periphery thereof, wherein the curved guide surface has a first convex portion for receiving articles from the conveyor, a second, convex portion, and a third, concave portion located between the first and second portions. Further concave and convex portions can be provided as required. For example, the surface may have a fourth, convex portion, and a fifth, concave portion located between the third and fourth portions.

As the size of the rotating surface increases, there is a greater chance that the vials will leave the rotating surface in a single row. Therefore, the size of the rotating surface, together with the position of delivery of vials on to the rotating surface, can be chosen such that the vials leave the rotating surface in a single row. In some circumstances, this could undesirably increase the size of the foot- print of the conveying system, and so in one preferred embodiment the system comprises a second conveyor for receiving articles from the rotating surface, the second conveyor preferably comprising a second rotating surface for receiving articles from the first rotating surface and a second conveyor guide surface for guiding articles transferred to the second rotating surface. At least part of the second conveyor guide surface is preferably curved so that it can complete the transition of the multi-row of vials into a single row whilst minimising the foot-print of the conveying system. In order to reduce the number of components of the system, the second conveyor guide surface is preferably continuous with the first- mentioned curved guide surface.

In order to enable any vials that have fallen or have been knocked out of alignment during conveyance to be rejected from the system, the second rotating surface preferably comprises a rotating annulus, and a deflector is preferably provided for deflecting any misaligned or fallen articles radially inwards away from the surface of the annulus, so that any such articles can fall from the system through the middle of the annulus. Thus, in a third aspect the present invention provides a conveying system comprising a rotating surface; a conveyor for conveying upright articles to the rotating surface; a rotating annulus; a first, curved guide surface for guiding articles received by the rotating surface towards the outer periphery thereof for subsequent transfer to the rotating annulus; a second guide surface for guiding articles received by the rotating annulus; and a deflector for deflecting any misaligned or fallen articles on the surface of the annulus radially inwards. In a preferred embodiment, the deflector comprises a third guide surface spaced from the second conveyor guide surface to define a channel for articles transferred to the rotating annulus, the third guide surface being arranged to deflect any fallen articles radially inwards away from the surface of the annulus.

Features described above in relation to the first aspect of the invention are equally applicable to the second and third aspects, and vice versa.

Preferred features of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 illustrates a plan view of part of a first embodiment of a conveyor system; and

Figure 2 illustrates a plan view of part of a second embodiment of a conveyor system.

With reference first to Figure 1 , a conveyor system 10 for conveying sterile vials between functions, for example, between a freeze dryer and a capping station, comprises a plurality of co-planar infeed conveyors 12 located side by side and moving in the direction indicated by arrows 14 in Figure 1 at either substantially equal or different speeds in the range, for example, from 2 to 12 metres per minute. Whilst two infeed conveyors 12 are shown in Figure 1 , the system 10 may comprise any number of infeed conveyors 12. Vials 16 are typically arranged on each of the infeed conveyors 12 in a plurality of rows, each row extending in the direction of the arrows 14. For example, up to ten rows of vials may be arranged on a single infeed conveyor 12.

A transfer device is provided for transferring the vials 16 on to a rotating surface 18, provided in this embodiment by a disc 18 rotating at a constant speed in the range from 2 to 12 rpm. The infeed conveyor 12 that is closest to the disc 18 is coplanar with and tangential to the disc 18 in order to ensure a smooth transfer of the vials from this conveyor 12 to the disc 18.

The transfer device comprises a lining belt 22 extending over the infeed conveyors 12 and the disc 18. The lining belt 22 has a surface 24 that is substantially orthogonal to the infeed conveyors 12 and the disc 18, and arranged obliquely relative to the infeed conveyors 12 and disc 18, that is, not along a radius of the disc 18. In this embodiment, the surface 24 of the lining belt 22 is at an angle θ of approximately 120° to the infeed conveyors 12, and the lining belt 22 moves at a constant speed in the range from 2 to 16 meters per minute and in the direction of arrow 26 shown in Figure 1. As indicated at 20 in Figure 1 , the size d of the distance, as viewed in the plan view of Figure 1 , from the location of the intersection between the surface 24 and the edge 21 of the infeed conveyor 12 adjacent the disc 18 to the location at which the edge 21 is tangential to the disc 18 is variable depending on the diameter of the vials 16 and/or speed requirements.

The transfer device also comprises a stationary, planar guide surface 28 substantially parallel to the surface 24 of the lining belt 22 and, which defines with the lining belt 22 a channel 30 along which vials 16 are conveyed as they are transferred from the infeed conveyors 12 to the disc 18. Moving the stationary guide surface 28 towards or away from the lining belt 22 as required can adjust the width of the channel 30 according to the diameter of the vials 16. In order to inhibit blockage at the mouth 32 of the channel 30, an unscrambling belt 34 is located adjacent the mouth 32, the unscrambling belt 34 being substantially orthogonal to the infeed conveyors 12 and the disc 18 and rotating in a direction indicated by arrow 36 in Figure 1 , that is, in a direction tending to urge vials away from the mouth 32 of the channel 30. This serves to separate the vials 16 as they enter the channel 30 and thus reduce both the pressure exerted on the vials 16 and the risk of channel blockage. A stationary, curved guide surface 38 is located above the disc 18 to guide vials 16 transferred to the disc 18 from the infeed conveyors 12. In this embodiment, a guide member 40 located above the disc 18 provides the curved guide surface 38. In this embodiment, the curved guide surface 38 extends outwards in the form of a spiral from one end of the stationary guide surface 28 of the transfer device towards the outer periphery 42 of the disc 18 in a direction of rotation of the disc 18, as indicated by arrow 44 in Figure 1.

A second rotating surface 46, in this embodiment in the form of an annulus 46, is located adjacent the disc 18 so as to receive vials from the disc 18. As indicated by arrow 48 in Figure 1 , the annulus 46 rotates in a direction opposite to the direction of rotation of the disc 18. In this embodiment, the annulus 46 rotates at a tangential speed that is equal to or greater than that of the disc 18. In this embodiment, the annulus 46 rotates at a speed in the range from 6 to 32 rpm. A second curved guide surface 50 extends partially about the external periphery 52 of the annulus 46 to guide vials 16 received from the disc 18. The second guide surface 50 is continuous with the first curved guide surface 38, and in this embodiment, the second curved guide surface 50 is also provided by the guide member 40.

Motors for operating the moving components of the conveyor system 10, that is, infeed conveyors 12, lining belt 22, unscrambling belt 34, disc 18 and annulus 46 may be conveniently located beneath the conveyor system 10. In use, with all components switched on, the infeed conveyors 12 convey a multi-row stream of vials 16 towards the lining belt 22. The lining belt 22 guides the vials 16 into the channel 30, and thus on to the disc 18. The surface 24 of the lining belt 22 serves to retain the vials 16 within the channel 30. As the vials 16 leave the end 54 of the channel 30, forces acting on the vials 16 serve to urge the vials against the first curved guide surface 38. At this point, the width of the stream of vials 16 leaving the channel 30 is generally greater than twice the diameter of the vials 16. With rotation of the disc 18, the first curved guide surface 38 serves to urge the vials 16 gradually outwards towards the periphery 42 of the disc 18. As the vials 16 move radially outwards, the tangential speed of the vials 16 increases. This in turn increases the spacing between the vials, and thus reduces the width of the stream of vials; as illustrated in Figure 1 , the width of the stream of vials towards the end 60 of the first curved guide surface 38 proximate the transfer device in Figure 1 is greater than that of the stream of vials towards the other end 62 of the first curved guide surface 38 proximate the annulus 46. In this embodiment, in which the diameter of the disc 18 is around 600mm, the first curved guide surface 38 serves to reduce the width of the stream of vials to less than 1.886 times the diameter of the vials 16. As the stream of vials 16 is transferred from the disc 18 on to the annulus 46, which is rotating faster than the disc 18, the stream of vials 16 adopts a single row configuration, as illustrated in Figure 1 at the end 64 of the second curved guide surface 50. The single row of vials 16 can then be transferred from the annulus 46, for example, to an outfeed conveyor 66.

By controlling the relative speeds of the moving components of the conveyor system 10, the position of the channel 30, and the shape of the curved guide surface 38, 50, the vials 16 can be accelerated and decelerated gradually through the conveyor system 10. This can reduce greatly the likelihood of the vials toppling as they are .conveyed through the system 10, and thus can enable the vials to be conveyed through the system 10 at a relatively high speed, for example, up to 600 vials per minute. In the event that any vials 16 should topple or become dislodged from the stream of vials, these will be discarded either from the periphery 42 of the disc 18, or through the middle 68 of the annulus 46.

As mentioned above, the shape of the guide surfaces 38, 50 of the guide member 40 can be modified as required, for example, in accordance with the diameter of the vials being conveyed by the system 10. Figure 2 illustrates a modified guide member 70, which is illustrated for use with a disc 18 having a 900 mm diameter although the modified guide member 70 may be used for other sized discs 18 (smaller or larger). In this guide member 70, the first curved guide surface 72 has a first convex portion 74 for receiving vials from the transfer device (not shown), a second convex portion 76 located proximate the annulus 46, and a concave portion 78 located between the convex portions 74, 76. The transition 80 between the concave portion 78 and the second convex portion 76 has been found to be promote separation of vials conveyed by the disc 18. Further concave and convex portions can be include as required.

Furthermore, unlike the second curved guide surface 50 in Figure 1 , the second curved guide surface 82 of the guide member 70 has been modified such that, whilst part of the second curved guide surface 82 continues to extend about the external periphery 52 of the annulus 46, another part of the second curved guide surface 82 is positioned over the annulus 46. This part of the second curved guide surface 82 defines with a third guide surface 84 located on a second guide member 86 a channel 88 along which vials 16 are conveyed for transfer from the annulus 46 to an outfeed conveyor 66. As shown in Figure 2, the third guide surface 84 is shaped so as to deflect any misaligned or fallen vials radially inwards so that they fall through the middle 68 of the annulus 46.

Claims

1. A conveying system comprising a rotating surface; a conveyor for conveying upright articles towards a transfer device for transferring articles from the conveyor to the rotating surface, the transfer device comprising a guide surface moving at a substantially constant speed towards the rotating surface and extending obliquely over the conveyor and the rotating surface; and a curved guide surface for guiding articles transferred to the rotating surface towards the outer periphery thereof.

2. A system according to Claim 1 , wherein the conveyor is located to one side of the rotating surface.

3. A system according to Claim 1 or Claim 2, wherein the conveyor is tangential to the rotating surface.

4. A system according to any preceding claim, wherein the transfer device comprises a second guide surface spaced from the moving guide surface to define a channel for articles transferred to the rotating surface.

5. A system according to Claim 4, wherein the second guide surface is stationary.

6. A system according to Claim 5, wherein the second guide surface is continuous with the curved guide surface.

7. A system according to any of Claims 4 to 6, wherein the guide surfaces are substantially parallel.

8. A system according to any of Claims 4 to 7, wherein the transfer device further comprises a third, moving guide surface located adjacent the mouth of the channel and moving against the direction of movement of the articles into the channel.

9. A system according to any preceding claim, wherein the curved surface extends outwards from the transfer device in a direction of rotation of the rotating surface towards the periphery of the rotating surface.

10. A system according to Claim 9, wherein the curved surface extends spirally outwards.

11. A system according to Claim 9, wherein the curved surface comprises a first convex portion for receiving articles from the transfer device, a second, convex portion, and a third, concave portion located between the first and second portions.

12. A system .according to Claim 11 , wherein the curved guide surface .. further comprises a fourth, convex portion, and a fifth, concave portion located between the third and fourth portions.

13. A system according to any preceding claim, comprising a second conveyor for receiving articles from the rotating surface.

14. A system according to Claim 13, wherein the second conveyor comprises a second rotating surface for receiving articles from the first-mentioned rotating surface and a second conveyor guide surface for guiding articles transferred to the second rotating surface.

15. A system according to Claim 14, wherein at least part of the second conveyor guide surface is curved.

16. A system according to Claim 14 or Claim 15, wherein the second conveyor guide surface is continuous with the first-mentioned curved guide surface.

17. A system according to any of Claims 14 to 16, wherein the second rotating surface comprises a rotating annulus.

18. A system according to Claim 17, comprising a deflector for deflecting any misaligned or fallen articles on the surface of the annulus radially inwards.

19. A system according to Claim 17, comprising a further guide surface spaced from the second conveyor guide surface to define a channel for articles transferred to the rotating annulus.

20. A system according to Claim 19, wherein the further guide surface is arranged to deflect any fallen articles away from the channel.

21. A system according to Claim 19 or Claim 20, wherein the further guide surface is arranged to deflect any fallen articles radially inwards and from the surface of the annulus.

22. A system according to any of Claims 14 to 21 , wherein the second rotating surface rotates at a tangential speed equal to or greater than the tangential speed of the first-mentioned rotating surface.

23. A conveying system comprising a rotating surface; a conveyor for conveying upright articles to the rotating surface; and a curved guide surface for guiding articles received by the rotating surface towards the outer periphery thereof, wherein the curved guide surface has a first convex portion for receiving articles from the conveyor, a second, convex portion, and a third, concave portion located between the first and second portions.

24. A system according to Claim 23, wherein the curved guide surface further comprises a fourth, convex portion, and a fifth, concave portion located between the third and fourth portions.

25. A conveying system comprising a rotating surface; a conveyor for conveying upright articles to the rotating surface; a rotating annulus; a first, curved guide surface for guiding articles received by the rotating surface towards the outer periphery thereof for subsequent transfer to the rotating annulus; a second guide surface for guiding articles received by the rotating annulus; and a deflector for deflecting any misaligned or fallen articles on the surface of the annulus radially inwards.