shenzhen penglai

The gel filling machine integrates mechanical, pneumatic and automatic functions. It has the characteristics of high automation, high yield rate, wide adaptability and good stability, and is therefore favored by the majority of users. The current model is becoming more and more perfect and mature, with high technical content, good adaptability and excellent quality, and is an ideal special filling equipment for gel manufacturers!

The machine has the functions of automatic tube sorting, automatic tube feeding, automatic tube detection (filling with tubes, no filling without tubes), filling (adjustable filling metering), automatic cap sorting and capping, and automatic capping. Compared with similar filling machines, this machine has stable operation, low noise, high yield rate, and easy maintenance, which is safe and stable. After the deepening of the process technology by our company's technical personnel, this machine can adapt well to the fully automatic operation of various types of tubes, and is an ideal gel filling equipment that fully complies with the GMP drug tube production specifications. This machine is suitable for the filling and production of ointments, cosmetics, glue, latex, gel and other products.

The appearance and structure of the gel dispenser filling machine can be divided into five parts: 1 centrifugal tube sorting machine/1 electromagnetic vibration outer cap sorting machine, 1 lifting feeder, and a gel filling host. The outer coat is sorted by a double-helix rotary sorting machine and a bottle conveying device and then enters a synchronous belt filling machine. The outer coat is then sent to each work station by the gap movement of the synchronous belt until all work processes are completed.

Performance and characteristics：

1. The pipe is centrifugal, with low noise and high speed.
2. The filling is driven by a servo motor, and the filling volume of each filling pump can be adjusted individually, and can be adjusted on the touch screen, which is convenient and fast.
3. The filling pump adopts a ceramic pump structure to increase the filling accuracy.
4. The lifting of the filling head is driven by a servo motor, which can better cooperate with the action of the filling pump and is easy to adjust.
5. The upper cover adopts vacuum suction and upper cover, and each suction cover head can be controlled individually to increase reliability. No tube, no cover.
6. It has the function of no filling and no cover without a tube or a push rod.
7. PLC touch screen control, with three levels of authority.

Automatic Syringes filling and capping machine ( Mark:The following machine information is for reference only. The machines need to be customized, please refer to the actual machine.)

Technical parameter of syringe filling capping machine model YX-PSF06:

Filling volume    1～5ml
Output    30-50 pieces/minute
Filling volume accuracy    ±1%
Number of filling heads    2 heads
Capping yield rate    ≥99%
Host power    5KW 380V stepless frequency conversion speed regulation
Filling transmission    Servo motor drive (2 sets)
Filling pump material    Ceramic pump (2 pumps)
Filling valve structure    Alumina ceramics
Management method    Centrifugal turntable tube management (1 set with elevator)
Cover management method    Electromagnetic vibration
Cover assembly method    Suction displacement assembly
Compressed air    ≥0.4~0.7mpa
Main material    The part in contact with the liquid is made of stainless steel 316, and the other parts are SUS304
Host dimensions    2500*3200*1800

Samples for the syringe machine:

Each part for whole machine:
(1)Automatic sorting and feeding part for syringe tubes

(2)Filling part:

(3)Automatic sorting, feeding and screwing of syringe caps

Principle and function description of each part of the machine:
(1)Automatic sorting and feeding part for syringe tubes

This unit is composed of 1 double centrifugal finishing machine, 1 lifting and feeding machine, and 1 lane dividing machine. The gel tubes are manually poured into the lifting machine hopper, and the centrifuge hopper photoelectric sensor controls the lifting machine to automatically feed. The gel tubes use centrifugal force to send the outer jacket out of the turntable, enter the customized slide rail, and then enter the lane dividing mechanism.

The 1-2 lane dividing machine is controlled by the main machine and moves in coordination with the operation of the main machine. The slide cylinder evenly pulls the gel tubes out of the track, and the rear cylinder pushes them into the conveyor belt track.                    

(2)Syringe Turnover system

The gel tubes to be filled are transported horizontally in the conveyor belt. When the tubes reach the end of the conveyor belt, they will enter a rotating support platform and the electric eye for tube turning detection will work. When it is detected that all the tubes have entered the rotating support platform, the computer controls the cylinder to move and extend the push rod. Through the action of the transmission connecting rod, the rotating support platform can be rotated 90 degrees, so that the gel tubes that were originally lying flat can be erected. At the same time, another tube-pushing cylinder will move to push the gel tube forward a certain distance, so that the gel tubes can smoothly enter the conveying groove of the working main turntable and wait for the next step of filling. A detection electric eye is also installed in the front of the tube turning mechanism on the conveyor belt. If the detection electric eye does not detect the existence of the gel tube, the turning action of the tube turning mechanism will be automatically stopped.

(3)Photoelectric detection station:

Used to decide whether to fill (fill if there is a tube, do not fill if there is no tube, and do not cap if there is no tube).
 
(4)Main machine transmission part: 

   This unit adopts chain-type intermittent conveying mode, and the intermittent motion adopts high-precision cam divider to drive the sprocket to drive the chain to complete the conveying action.

(5)Filling part:

This unit uses piston metering, high liquid level, pneumatic rotary valve, and servo drive for piston movement. When the gel tube reaches the filling station, if the previous photoelectric detection detects the presence of the tube, that is, filling is allowed, the internal chip sends a filling signal.
    
This unit adopts piston metering, high liquid level, pneumatic rotary valve, and piston movement is driven by servo motor. When the gel tube reaches the filling station, if the previous photoelectric detection detects the existence of a tube, that is, filling is allowed, the internal chip sends a filling signal.

When the gel tube to be filled enters the filling device station, the internal control chip controls whether to fill (filling if there is a tube according to the previous sensor, and no filling if there is no tube), the filling gun head drops into the tube, the filling cylinder opens the filling valve, and the gel is automatically poured into the tube.

——When the gel tube reaches the filling station, if the previous tube detection station detects the existence of a tube, that is, filling is allowed, the filling device will perform the filling operation.
——The metering cylinder is now pulled downward under the action of the metering cylinder push rod (as shown above), and the valve shaft rotates to close the front sealing surface, that is, the specified amount of gel is sucked from the upper gel barrel into the metering cylinder. The metering adjustment is completed by the dosage regulator.
——The internal control chip will rotate and control the filling cylinder according to the program control. The cylinder is mainly used for the reversal of the filling rotary valve, that is, when there is a filling signal, the cylinder acts to turn the rotary valve and fill the gel in the metering cylinder from the filling gun mouth; if there is no filling signal, the cylinder does not act, and the gel in the metering cylinder returns to the upper gel barrel, which is equivalent to a "dry shot". In this way, the purpose of filling with bottles and not filling without bottles is achieved.
——If the presence of a bottle is detected in the front, the filling cylinder will operate to move the valve core backwards, close the rear sealing surface so that the gel in the barrel cannot flow into the metering cylinder, and at the same time, the metering cylinder push rod moves upward, squeezing the gel out of the metering cylinder, thereby completing a filling operation.

(6)Filling control valve

Filling control valve
The function of the filling rotary valve is to control the filling, and the filling work can be carried out smoothly through reasonable motion control.
The working order is as follows:
-When the machine rotates continuously, the gel liquid is sucked into the metering cylinder from the upper barrel. At this time, it is equivalent to the upper part of the valve core connecting the liquid barrel port and the lower part connecting the metering cylinder port (at this time, the position of the valve core is blocked to the front sealing surface). That is, the operation of sucking a certain amount of gel liquid from the barrel is completed.
-Next, the machine will determine whether to fill according to the signal detected by the front tube (filling with tubes and no filling without tubes). If filling is required, the valve shaft will rotate a certain angle under the drive of the filling cylinder (as shown above), so that the upper and lower ports of the filling rotary valve are disconnected, and the metering cylinder port and the filling joint port are connected. In this way, when the piston inside the metering cylinder is lifted upward, the liquid inside the metering cylinder is pressed out to complete a filling.

(7)Automatic cap sorting:

Electromagnetic vibration capping machine, variable frequency control speed regulation           

(8)Automatic cap feeding:

The outer cap is taken by vacuum suction. The caps are sorted by the electromagnetic vibration capping machine and transported to the capping station in sequence by the parallel vibrator. It is also based on the signal of the previous photoelectric detection. If the detection signal shows that there is a tube on the station, the internal control chip will control the X-axis (front and back) and Y-axis (up and down) cylinders to cooperate with the vacuum valve to suck the outer cap and then drop it onto the gel tube mouth. The whole set of actions is compact, the structure is reasonable, the accuracy of capping is high, and it is an active capping. In addition, the cylinders of each channel are individually controlled by a computer, so that no capping can be achieved without a tube.

(9)    Capping Section;

The outer cap pressing part is driven by a mechanical Geneva wheel to make the swing arm press down. The Geneva wheel is designed for 2 downward pressing actions. Moreover, the pressing head can be adjusted up and down and is equipped with a spring buffer to avoid damaging the outer cap.     
 
(10)    Discharging station: 

This station completes the output of the final filled product. The product is sent out from the inclined track onto the conveyor belt by the action of the discharging fork.

Configuration of syringes filling sealing machine rotary type:

No    Name    Models and specifications    Unit    Number    Note
1    Programmable controller    SIMATIC S7-200 SMART    set   1    Siemens (imported)
2    Touch screen    6AV6 648-0DE11-3AXO    set    1    Siemens (imported)
3    Frequency converter    FR-D720SE-0.75K    set    1    Mitsubishi (imported)
4    Servo motor    MR-JE40A    set    3    Mitsubishi (imported)
5    Servo drive    HG-KN43J-S100    set    1    Mitsubishi (imported)
6    Circuit breaker    N47-63/10A    pc    1    Schneider (imported)
7    Contactor    B9    pc    1    Schneider (imported)
8    Speed regulator FS32B    pc    3    Shanghai
9    Solenoid valve    4V210-08/24V    pc    10    AirTAC (Taiwan)
10    Switching power supply    S-100-24    pc    2    Taiwan Mean Well
11    Detection photoelectric    5TW-1116    pc    4    Pepperl+Fuchs
12    Proximity switch    GK5m-1N    set    10    Pepperl Fuchs
13    Fiber optic & amplifier    V-153-1C25    pc    12    Keyence (imported)
14    Relay    MY4NJ    pc    10    Omron (imported)
15    Three-phase asynchronous motor    YS7134    pc    1    Dedong
16    Single-phase speed regulating motor    51K120RGU-CF-15K  pc    1    Zhongda
17    Single-phase speed regulating motor    5IK120RA1-CF    pc    1    Zhongda
18    Reduction motor    RV063-30K    pc    1    Ouhai
19    Reduction gear    WPWK-70    set    1    Shanghai Lihai
 20    Reduction motor    RV030-30K    pc    1    Ouhai
21    Servo electric cylinder    HHM802-S1101P05C7ASFE2NA04DNO-0    pc    2    Honghe
23    Ceramic pump    YS-03    set    2    Dachang
24    Pneumatic components                Festo
25    Tube module    Polypropylene            China
26    Conveyor belt    Components (PU)            China
27    Filling system    Components            China
28    Material    The part in contact with the liquid is 316, and other outer parts are SUS304
Note: The models and specifications of the listed products may be adjusted and modified during design based on user needs and actual conditions.

ALL RIGHTS RESERVED by ^®PENGLAI MACHINES LIMITED