1. Tidy up the catheter, because the catheter is coiled in a circle, and after a certain amount of time in
storage, the catheter will deform in the direction of the coil. At the same time, because the conduit is made of plastic, and the slit is very small, so the unavoidable static electricity will also bring a lot of trouble in the processing.
2. Catheter and the needle holder is generally fixed using rivets, in the insertion of rivets before the fixed end of the catheter
The catheter needs to be expanded at a certain angle to facilitate the insertion of rivets, due to the material of the catheter, this process will be very difficult. Some manufacturers use a non-expanded way directly into the fixed rivets to improve efficiency, but even so, the insertion of small rivets will still bring a lot of trouble.
3. The conduit requires a specially shaped tool to be pushed into the bottom of the header, and there are precise
positional requirements.
4. Because of the special needs of the indwelling needle, the catheter tip needs to be processed into a certain shape, and the manual
use of catheter tip molding machine to gradually mold the catheter tip, at present, there is still a lot of room for improvement in the production capacity of the domestic production of tip molding machine and molding quality.
5. Manual insertion of the syringe into the needle piece, due to the precise strength and length requirements, so it can not
efficiently completed
6. In the syringe and infusion tube dispensing, some domestic manufacturers will be with the help of some simple homemade
tools to complete the process of dispensing, because dispensing in the manual process is a job that can not be data, and the operator has high requirements. Personnel have high requirements, usually, training a skilled dispensing workers need 1-2 years, but, dispensing in the product quality of the needle in the proportion is self-evident. Secondly, because of the special characteristics of the indwelling needle products, there are a lot of tedious but necessary quality tests, which can not be avoided in the process of manual production, such as
1. The bonding force test of the needle tube and the needle piece, which is a quite important test, if the bonding force of the needle tube and the
needle piece is not enough to meet the requirements, the result is that the needle tube will fall off because of insufficient bonding force, thus the needle tube will fall off because of insufficient bonding force, which is not enough to meet the requirements of the needle tube. The result is that when the needle is removed after insertion, the needle will fall out due to insufficient bonding, which can further lead to various possible medical errors.
2. The shape of the catheter tip is what ensures that the catheter can be inserted smoothly into the patient's vein, and in the absence of this
process, various catheter tip quality issues can lead to patient pain or insertion failure.
3. As in the previous section, testing the integrity of the catheter and tip is critical to ensure that the indwelling needle can
smoothly penetrate the body. In addition, such as catheter tension test, airtightness test, and the overall length test of the catheter and the needle base all belong to this category. In reverse, even if the manufacturers are able to carry out the above work smoothly, they still cannot produce large quantities of products because these are based on the possession of a large number of human resources, and there is also another important problem that cannot be avoided, namely, it is not possible to guarantee the quality of the products in a stable way, mainly because of the special nature of the quality testing The main reason for this is the specificity of quality testing. First of all, the manual state can not be effectively tested, such as:
1. Various types of length testing, basically by the ruler, precision and efficiency are very low and will bring a
a certain probability of misinterpretation.
2. catheter tip detection rely on the naked eye and magnifying glass, no quantitative data can be referred to, only
can detect similar fringe, major deformation only
3. needle and catheter fit tip detection rely on the naked eye and magnifying glass, no quantitative data can be
referred to, can only be detected similar to the fringe, major deformation only, and secondly, some of the tests are destructive. Secondly, some tests are destructive and can not be completed under manual conditions, such as syringe tension test, catheter tension test, generally do the sampling test, can not monitor the quality of all finished products 100%. In addition, there are other tests that are difficult to perform under manual conditions, such as air tightness testing.
Let's take a look at how these problems are rationally and effectively solved on KAHLE's fully automated assembly line.
First, let's look at the process flow. Here is a list of some of the important work stations.
1. On the KAHLE machine, before the tube is cut to length, it passes through a heated straightening unit
this unit softens the tube quickly, and then, with the assistance of a tensioning mechanism, a cooling unit, and a de-staticizing unit, the tube enters the cutting unit in an optimal state, and then, after precise length control, the optimal state of the tube enters the machine. After precise control of the length of the slitting, a section of the conduit in the best condition enters the machine running process, which is embodied in the machine, in the conduit feeding unit has completed all the actions.
2. Expansion of holes in the assembly line is achieved by high-frequency heating head with molds, which is more efficient and accurate than manual expansion of holes by transmission
.
3. The robot inserts rivets quickly and efficiently
4. The fastening of the conduit to the header is achieved with a push-in tool combined with a thrust gauge
This cumbersome task in the manual process is solved by a single station, and has the unsurpassed advantages of manual operation, where the force and depth can be adjusted according to the different products and the data from the thrust gauge is fed back in real time. The force and depth can be adjusted according to different products, and the thrust meter data is fed back in real time.
5. Almost the most important step in manual production in KAHLE's fully automated assembly line
was simplified to a few stations, the use of different products can be arbitrarily set according to the temperature of the high-frequency heating unit and molds with the assembly line can easily process the products need to the shape of the tip of the catheter, in order to ensure the quality of the molding, the high-frequency machine is also equipped with water-cooled cooling unit effectively prevent the thermal adhesion caused by all kinds of In order to ensure the quality of molding, the high frequency machine is also equipped with water cooling unit to effectively prevent all kinds of catheter quality problems caused by thermal adhesion, and can complete the tip molding inspection on the assembly line.
6. Silicone oil is an indispensable lubricant in the production of indwelling needles. In manual production,
applying silicone oil is a cumbersome task, but in the assembly line, the specially designed silicone oil steel and silicone oil applicator unit can effectively wet the silicone oil at high speeds and there are corresponding excess silicone oil removing devices for the parts that may lead to contamination.
7. Shape inspection is fully visualized and included in the workflow, as described in the next
section.
8. Needle insertion into the needle blade is more accurate than in the manual method, and the needle is dispensed at the point where the needle meets the needle blade, a step that can be seen as redundant in a fully automated assembly line for reasons described in detail below
9. Dispensing, a cumbersome problem in the manual method, is simplified in the fully automated assembly line
into a single spray station, where glue can be dosed and dispensed in one step. The glue can be sprayed quantitatively and the amount of glue can be adjusted at any time.
10. In the operation process of the assembly line, all the waste or unqualified products produced by the process are
automatically rejected by the device or station and have the corresponding recycling device.
Then look at the fully automated assembly line compared to the manual method of inspection unit work
1. All the length of the inspection in the assembly line to a limited number of workstations or inspection means to determine
.
2. Catheter tip inspection and syringe and catheter tip fit inspection are all based on high precision image inspection
Vision system, the camera system automatically locates and scans the catheter tip, the inspection system automatically analyzes the scanning result and determines whether it is good or not according to the product data inputted in advance, then the system displays the scanning result in the form of image and data on the display screen, which is convenient for the operator to monitor, and at the same time, the inspection result is fed back to the operator for monitoring. Then, the system displays the scanning results in the form of images and data to the display screen for easy monitoring by the operator, and at the same time feeds the results back to the assembly line processor to complete the reject process, which is an independently operated sub-system equipped with a specialized processor and integrated into the work program of the entire assembly line.
3. Needle inserted into the needle holder when the thrust detection, insertion thrust to determine whether the needle holder and
needle combination is solid, so there is no need for manual dispensing of this link, the premise is that the quality of the needle parts over the quality of the actual application of the station's yield is almost 100%.
4. catheter tension test using the method of counterweight in a changeable test standard workstation
to test the catheter and the Y seat bonding force, after the completion of the test, the catheter is clamped part of the catheter will be automatically excised PPT
5. airtightness testing workstation, the catheter and the infusion tube will be sealed by the robots, stamping after the use of
data-based detection to determine whether or not the sealing, the way to determine the sealing, and the way to determine whether or not to manually dispense glue. After stamping, data-based testing is used to determine whether or not it is airtight. Testing that is difficult to complete manually is monitored in just one station on the assembly line.
6. gQuality inspection is all included in the assembly line process, all the inspection stations
can feedback the inspection results to the assembly line and reject the waste products in the reject station, and the products come out from the discharge port are all the finished products that passed the inspection.
In addition to the above, KAHLE's fully automated assembly line is also quite advanced in the following aspects.
With a simple and efficient menu control panel (HMI), which can be set up in multiple languages according to customers' requirements
And according to customers' requirements, the production data of various specifications of indwelling needles are built into the machine, and it is very simple to select the product specifications that the production parameters of the whole machine can be adjusted to the data required for changing the specifications, and the production yield of the machine can be queried at any time and the yield situation of various kinds of products can be queried separately according to the workpiece and the workstation. All kinds of components can work manually and automatically, which is convenient for maintenance and repair, and it only takes one touch on the LCD panel to change them.
With perfect alarm and safety system, such as safety door alarm, in the open state, the machine will not be able to enter the working state, all kinds of action components are not placed in the correct position, the machine will be alarmed and the machine will be transferred to the protection state, in addition, each station and the production process are in the system monitoring, the system will be in accordance with the situation of the alarm to take a variety of different ways of warning, including sound and light warning, the machine in different working conditions, the machine will be in a different workplace, the machine will be in a variety of different ways of warning. The machine is equipped with emergency stop buttons on all different working surfaces to ensure that the operator can stop the machine at the first time if an abnormal situation occurs. The system also detects all sensors in the system to ensure that they are working properly.
KAHLE's assembly line in the electrical system, for each individual subsystem has a special insurance and safety electrical components, each cable has its own wire groove, and the use of hidden alignment, greatly ensuring the simplicity of the machine, all electrical connectors are used in line with industrial standards of the connector, to ensure the compatibility of the machine, all the cable connector are labeled, easy to detect and maintain. All cables are labeled for easy inspection and maintenance.
KAHLE assembly line in the PLC and HMI unit can be connected through the ordinary PC to all kinds of connection and adjust the software parameters, and even manually adjust the action components work, and through the PCl to adjust the machine to adapt to the production of new products or a variety of software parameters change in specifications, KAHLE engineers can even be through the INTERNET network to remote testing KAHLE's engineers can even remotely inspect and upgrade the customer's assembly line via INTERNET network. All the customer needs is a computer with Internet access and the corresponding software (provided by KAHLE), which ensures the timeliness of the work to the greatest extent possible.
Besides the fully automated assembly line for indwelling needles, KAHLE is at the forefront of suppliers of disposable medical assembly equipment in more ways than one. In some cases, it has even become the industry standard for cutting-edge technology. --This article comes from the medical community