At present, it is no longer a slogan to realize modern packaging of traditional Chinese medicine. Through the continuous guidance and encouragement of the country, and the joint efforts of various pharmaceutical equipment manufacturers and pharmaceutical companies, China's modernization of Chinese medicine packaging has taken a big step forward. Although the road is still long, it has already formed an inevitable trend. Under this trend, it is believed that the road to modernization of Chinese medicine packaging will go much better.
In China, the production and packaging of traditional Chinese medicines still remain at the traditional level of manual work. There are too many objective and subjective reasons. The first is the special physical and chemical properties of traditional Chinese medicines, and the second is the special production process of traditional Chinese medicines. Of course, there are a series of other reasons.
As a commonly used form of traditional Chinese medicine, dripping pill has the universal characteristics of traditional Chinese medicine. In the low-humidity, air-drying production vehicles, the dripping pills produced through the processes of concentration, centrifugation, and coating have the characteristics of strong electrostatic interference, high viscosity, and fragility, as well as a large number of fillings per bottle. Bottles are mostly shaped bottles, which have small bottle openings, light bottle caps, etc. The positioning and gripping of the bottles during the filling process is very difficult and can also cause certain difficulties for the grains. At present, foreign packaging equipment can not solve the problems in the filling process, so in China, most of the pill pills are still filled by hand, which greatly increases the filling time and the probability of cross-infection. , Drip pill filling has also been stuck in the packaging technology is relatively low level. Zhejiang Shenglei Machinery Co., Ltd. based on a large number of market research, is mainly to in-depth understanding of the dripping pills production process, the physical properties of the produced pills and filling the environment for research, to overcome one of the pill pill filling The difficult problem caused it to bid farewell to the original stage of manual filling and opened a new chapter in the automated filling of dripping pills.
The intelligent Chinese medicine drip pill filling machine researched and developed by Shenglei Company is a collection bottle, bottle extension, cloth pill, number of tablets, filling, capping, renewal cap, screw cap, inspection, rejecting, finished product transportation and other processes. Integrated modular overall style structure. The bottle turning mechanism, the dropping pill filling and feeding device, the capping device and the intelligent management system adopting language alarm, image simulation, fault diagnosis, man-machine dialogue, etc., make the device have a reasonable structure, small size, high degree of automation, Pill counting accuracy, operation and maintenance, easy cleaning and so on. At the same time, the automatic bottle filling technology also fills the domestic gap.
In the process of automatic pill pill filling, the intelligent Chinese medicine pill pill filling machine mainly solves the following problems:
1. Bottle renewal mechanism The traditional dripping pill filling is mostly based on shaped plastic vials with anti-counterfeit properties. These types of bottles are small in size, light in weight, difficult to handle, and difficult to control. For these characteristics, St. Ray company designed the renewal bottle turn mechanism, using a unique high frequency and low noise dual vibration platform and automatic centering mechanism, so that the scattered vials through the vibration, orderly into the bottle guide, and then down The guide rail then enters into a heading mechanism consisting of a unique rocker adjusting flap to perform a heading. Finally, the bottle is aligned with the bottle mouth in a predetermined state, and the ordered bottle is entered into the drum via a fully enclosed retractable torsion spring. Inside the bottle storage box, make full preparations for filling. The bottle turning mechanism has been granted a national utility model patent.
2. Dripping Pills Filling and Feeding Due to the traditional Chinese Medicine Dripping Pills in the manufacturing process, they are carried out in the purification plant. The humidity inside the workshop is small and the air is dry. The manufacturing of the dropping pills is carried out through processes such as concentration, centrifugation, and coating, and a dropping pill. The small diameter and large difference in shape result in many unfavorable factors such as the dropping pill pilling, pilling, filling, and particle detection. For these physical characteristics of the pill and the objective environment in the workshop, St. Ray designed a filling and feeding device for the dropping pills to solve the problems in the automatic filling of the dropping pills.
(1) Fabric pill: Due to the high viscosity of the dropping pills and the strong electrostatic interference, the dripping pills suck and adhere to each other during the feeding process, and they cannot enter the bolus hole smoothly, directly affecting the filling speed and quality (drops). Pill filling requires each bottle to have a certain number of grains, and the number of grains is inaccurate is unqualified product), resulting in a marked decrease in the filling qualification rate, so that the comprehensive advantages of machine filling can not be reflected. In the process of design, Saint Ray company designed an embedded crawler type grain feeder for this problem. The conveyor belt of the crawler-type grain feeder consists of several embedded strips that are injected with PE material with static-free properties. The pellets are provided with holes matching the size of the dripping pills, the back has a pilling groove, and the two sides are equipped with magnets, so that each pellet is formed into a special conveyor belt by the compression of the magnets and the adsorption of the magnets. The main body of the device. The feeder has the characteristics of high pill rate, no cutting, high precision, small size, light weight, easy cleaning and disinfection. And, according to customer needs, it is convenient to adjust the filling volume of each bottle. When changing the amount of filling, it is only necessary to replace the number of pieces with a number of holes and a number of pieces without holes, and it is in full compliance with GMP requirements.
(2) Pellets, filling, and several grains detection Due to the electrostatic discharge of the dripping pills, the dripping pills are sucked and overlapped when filling the pills, resulting in unbalanced pilling and easy clogging of small funnels during filling. The filling can not be carried out smoothly. For this feature, we designed a scraper-type guide groove and a micro-vibration device, and successfully solved the above problems.
3. Differential capping device The traditional capping cap is generally divided into three types, namely the rotary type, the claw type, and the pressure rotary type. A claw pressure type capping device has been designed for this type of drip pill filling machine. This device uses the principle of positive and negative rotation, through the small motor forward and reverse rotation and cylinder reciprocating motion, complete the capping action. Each time before capping, the cap and the bottle mouth are automatically aligned by an anti-rotation action, which greatly improves the pass rate of the cap.
4. Intelligent control system and camera inspection With the deep implementation of domestic GMP standards, modern pharmaceutical companies have put forward higher requirements for the unmanned design of packaging equipment. This means that the fault self-diagnosis function and control function of the equipment and the perfect feedback adjustment function with the environmental change determine the dependence of the equipment on people, and thus determine the standardization of product quality control and quantitative control and reliability. Degree. The Chinese medicine drip pill filling machine control is based on the principle of design and development of intelligent systems, the main function is to monitor the machine's operating status and external environment changes, so that feedback control based on the actual situation, mainly the following points :
(1) Calculate the number of filled pills by the intelligent linear CCD high-speed counting system on the system, and send the data to the main control system through the cascaded data bus.
(2) Through the various levels of sensors on the system (such as: code disk, photoelectric sensors and pressure sensors in various places, etc.) to learn the operation stage of the machine, whether the actions of each stage are performed correctly, and whether the relevant physical quantity parameters are correct.
(3) Through the various levels of sensors on the system (such as: code disk, photoelectric sensors and pressure sensors in various places, etc.) to learn the operation stage of the machine, whether the actions of each stage are performed correctly, and whether the relevant physical quantity parameters are correct. Based on this information, the master control system automatically queries its internal database for corresponding processing steps. Once uncovered parts of the system are found, the system calls for an internal alarm information library and provides the fault information it encounters to the professional maintenance personnel through the display screen.
(4) Another major function and characteristic of this system lies in the extensibility of its system. Taking into account that most pharmaceutical manufacturers often use different doses of filling for different drugs, intelligent Chinese medicine pill filling machine reserves a corresponding setting module in the system to complete the filling quantity, filling speed, bottle detection sensitivity And the same day production presets and other functions. At the same time, in order to prevent misoperations, the input passwords are encrypted for these modules.
(5) Considering more and more manufacturers' demands for intelligent production workshops, intelligent Chinese medicine pill filling machine has reserved high-speed communication modules inside the system. According to the needs of customers, it is very convenient to add different physical interface modules. Through these physical modules and the high-speed software communication module inside the system, the host computer can implement data access and command release within the system according to the provided command format or directly call the provided dynamic link library (.dll).
The control system can be structurally divided into a three-level system or a quasi-quadruple system. Each level is a passive induction sensor, an active data acquisition sensor, a PLC control system, and an upper computer control system that can be optionally added. The following sections will address the features of each level and the functions performed.
1. Passive inductive sensor is a complex mechanical motion control system. It requires various types of sensors to convert the physical quantities required by the system (such as voltage, air pressure, etc.), and the displacement and angle of mechanical components into control. The amount of electrical signal that the system can recognize. The data collected by these sensors from the main control system constitutes the working status database of the system. By comparing the database with the contents of the preset template database, the system control steps required by the execution unit of the system are analyzed.
2. Active Data Acquisition Sensors Since the collection of some physical quantities requires multi-dimensional control over time and space, simple passive inductive sensors obviously cannot perform these tasks. For example, a number of institutions fall into this category. When Saint Lei company designed the intelligent Chinese medicine pill filling machine, based on past products and existing actual conditions, this subsystem was discussed in-depth.
In the past, companies often used circuits consisting of high-speed infrared emitters and light-emitting diode receivers to achieve a number of particles. However, it was later discovered that the size of most light emitting diodes and receiving diodes far exceeds the distance between the dropping paths of the dripping pills, which means that it is impossible to install a detection system on the guiding flutes. At the same time, due to the small mass of the pill and its mutual exclusion characteristics, the pill quickly deviates from the vertical drop path after leaving the guide channel. As a result, a signal-capturing model similar to the "regarding waits and waits" adopted by a system composed of light-emitting diodes cannot be used because the pills do not follow the desired route. As a result, the lateral resolution of the system needs to be improved.
Therefore, St. Ray company also tried to shoot with a high-speed camera, and then carry out a number of tablets. However, since the existing camera systems are difficult to keep up with the speed at which the pills fall, most of them obtain a "tail" image, so data analysis cannot be performed at all.
Based on the above experience, what is needed is an imaging detection system with high-speed response and high resolution at the same time. Therefore, the vision of Saint Ray company falls on the linear CCD. The intelligent CCD pill filling machine's CCD drop counting system uses the international leading blue lens imaging optical system and SONY's color CCD. The system uses a precision optical system to project the detected 77mm width onto the CCD image plane with 3000 pixels. This achieves a resolution of 38pixels/mm, and it is completely possible to distinguish the dripping pills with a diameter of 3.2±0.15mm. And 1000 times / second scanning speed can guarantee 5 to 6 times / pill's capture rate. At the same time, since the linear CCD is a continuous imaging device, it can capture dripping pills that run in any path.
3. PLC control system This system uses Mitsubishi's FX1N module as the main control module of this system. Different and previous development ideas, it uses a new modular design program, that is, according to the needs of the tasks to be divided, including the following sub-modules.
(1) The data acquisition submodule is mainly responsible for each transmission