Reduction of human interventions on filling machines operating in sterile environment

This graduation thesis describes the development of a project on a sterile packaging automatic machine, designed to fill vials with a liquid pharmaceutical product. The distinguishing feature of this automatic machine is the magnetic levitation transport system used to carry vials along the machine. It is realized with a Planar Motor, that is composed by a defined flying surface and movers that are free to move above it, carrying vials. Such transport system gives notable advantages in terms of flexibility and sterility. During the filling process, it is important to verify the dosing precision by weight-checking vials. Balances need to be maintained, to ensure accurate weighing. The project goal was to automate the process of balances maintenance (e.g. calibration). The core idea is to exploit the magnetic levitation transport system: a mover would carry the calibration weight and place it on balances, instead of having an operator to do it manually. Realization of such functionalities required to understand how the transport system can be controlled and to manage the sequence of actions to perform maintenance operations, while providing an intuitive interface for the operator. The developed code allows the operator to perform any balance maintenance operation by just interacting with the HMI. Maintenance can be performed before or while the production cycle is running. In the latter situation, the production flow is stopped temporarily, to allow maintenance operations to be performed, then it is resumed automatically. During the maintenance process the calibration weight is placed on balances automatically, when needed. Performing balances maintenance automatically gives advantages not only in terms of usability, but also sterility, required time and safety.