WO2020220752A1 - 一种药液灌装控制***、灌装***及控制方法 - Google Patents

一种药液灌装控制***、灌装***及控制方法 Download PDF

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WO2020220752A1
WO2020220752A1 PCT/CN2020/071498 CN2020071498W WO2020220752A1 WO 2020220752 A1 WO2020220752 A1 WO 2020220752A1 CN 2020071498 W CN2020071498 W CN 2020071498W WO 2020220752 A1 WO2020220752 A1 WO 2020220752A1
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filling
liquid medicine
pump
liquid
medicine
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PCT/CN2020/071498
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English (en)
French (fr)
Inventor
刘志
谢欢
刘龙
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楚天科技股份有限公司
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Publication of WO2020220752A1 publication Critical patent/WO2020220752A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B3/00—Packaging plastic material, semiliquids, liquids or mixed solids and liquids, in individual containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, or jars
    • B65B3/26—Methods or devices for controlling the quantity of the material fed or filled

Definitions

  • the invention mainly relates to the technical field of medicine and food packaging, and specifically refers to a liquid medicine filling control system, a filling system and a control method.
  • the liquid medicine filling usually uses a positive displacement pump.
  • the mass of the medicine liquid is generally obtained by weighing the medicine bottle before and after filling, and then the density is converted into
  • the volume filling method is used to obtain the actual filling volume of the medicine bottle, and then the actual filling volume obtained is compared with the set filling volume, and the calibration is realized according to the difference between the two.
  • the patent document CN102460091B discloses that the first weighing device is used to weigh the empty container, and the second weighing device is used to weigh the container filled with the product, thereby realizing the measurement of the medicine.
  • the methods and structures of such measurement and calibration have the following problems:
  • the weighing system requires very high environmental requirements and installation accuracy, and its own structure is complex, the manufacturing cost is high, installation and debugging is more troublesome, and there are many auxiliary devices, including static elimination devices, shock absorption devices, weighing channels and driving devices And so on, so the overall cost of the entire weighing system is very high.
  • auxiliary devices including static elimination devices, shock absorption devices, weighing channels and driving devices And so on, so the overall cost of the entire weighing system is very high.
  • the structure of the first weighing device, the second weighing device and the related conveying device are complex and costly.
  • the empty bottle When the weighing system is used to verify the filling volume of the filling pump, the empty bottle must be weighed first, and then weighed after filling, and it takes a certain time for the weighing to reach a steady state. Therefore, running the weighing system takes a lot of production time, and the equipment capacity is greatly reduced, which reduces the production efficiency.
  • the equipment capacity is greatly reduced, which reduces the production efficiency.
  • the weighing system when the weighing system is used to verify the filling volume of the filling pump, only sample weighing can be used for calibration , There is a risk of producing substandard drugs. For example, in the patent document CN102460091B, it is necessary to weigh the empty bottle and the filled bottle separately, which not only affects the filling efficiency, but also affects the conveying efficiency.
  • the accuracy of the volume V depends on the quality and density of the liquid medicine. But first, the composition of the medicine is complex, and many liquids are mixed before filling, so it is difficult to obtain the accurate density of the liquid; second, the precision of the high-precision electronic scale used for weighing the liquid is relatively high. High, but this kind of electronic scale also has very high environmental requirements. For example, machine vibration, hundred-level laminar wind, surrounding magnetic field, static electricity generated during liquid medicine filling, etc. will affect the accuracy of weighing. The above two factors lead to the accuracy of the loading volume cannot be guaranteed.
  • the present invention provides a filling control system and a filling system with high filling accuracy and efficiency, and a simple structure, and a corresponding filling Liquid medicine filling control method with high accuracy and efficiency.
  • the technical solution proposed by the present invention is:
  • a liquid medicine filling control system includes a control unit and a flow sensor; the control unit is connected to the flow sensor; the flow sensor is used for real-time detection of a filling pipe connecting a filling pump and a filling head The liquid medicine flow rate or the liquid medicine volume; the control unit is used to obtain the actual filling volume L1 of a single filling of the medicine bottle according to the medicine liquid flow or volume, so as to calibrate the single filling stroke of the filling pump to form Closed-loop control.
  • the flow sensor is a non-contact ultrasonic sensor.
  • the flow sensor is fastened to the filling pipeline by a clamp.
  • the present invention also discloses a liquid medicine filling system, which comprises a liquid reservoir, a filling pump and a filling head, and also comprises the liquid medicine filling control system as described above; the input end of the filling pump and the filling head The reservoir is connected, the output end of the filling pump is connected to the filling head through a filling pipe, and the control end of the filling pump is connected to the output of the control unit in the liquid medicine filling control system. End connected.
  • the invention also discloses a liquid medicine filling control method, which includes the steps:
  • the actual filling volume L1 corresponding to the medicine bottle is obtained from the liquid medicine flow rate during the filling process, and then the difference A between the preset target filling volume L and the actual filling volume L1 is obtained;
  • step S05 when the average deviation ⁇ A is greater than the preset allowable filling quantity deviation range a%, the single filling stroke of the filling pump is calibrated, otherwise it is not calibrated.
  • step S03 when the difference A is not less than the limit loading deviation b%, it is judged that the medicine is unqualified, and an alarm is given to shut down.
  • step S04 the average deviation ⁇ A is obtained by averaging the N difference values A; or after removing a maximum value and a minimum value, the average deviation ⁇ A is obtained by averaging.
  • step S01 a non-contact liquid flow sensor installed on the filling pipeline is used to detect the flow of the liquid medicine in the filling pipeline in real time.
  • the flow sensor is not affected by the surrounding environment during measurement, no additional auxiliary devices are needed, the structure is simple, the cost is saved, and the installation and debugging are very convenient, and the labor productivity is improved; in the filling process Real-time detection of the liquid medicine flow in the filling pipeline to obtain the actual single filling volume L1 corresponding to the medicine bottle, that is, the detection process and the filling process are carried out simultaneously, avoiding the need to add other processes before and after the filling in the similar weighing link. Thereby improving the overall filling efficiency; and the overall structure is simple and easy to implement.
  • the liquid medicine filling control system of the present invention adopts a completely different idea from the way of weighing before and after the medicine bottle is filled to obtain the actual filling amount L1, but uses a flow sensor to measure the flow rate of the medicine liquid entering the medicine bottle on the filling pipe.
  • the volume is directly detected to obtain the actual filling volume L1 each time, and then feedback to the control unit according to the actual filling volume L1 to realize the closed-loop control of the filling pump, thereby improving the filling accuracy and reducing the unqualified filling volume risk.
  • the liquid medicine filling control system of the present invention detects the liquid medicine flow rate or the liquid medicine volume in the filling pipeline through the flow sensor, and directly obtains the actual filling quantity L1, without the need to adopt the mass, density, etc. required in the weighing link Conversion reduces uncertain factors and improves the accuracy of calibration.
  • the liquid medicine filling control method of the present invention also has the advantages described in the above control system.
  • liquid medicine filling system of the present invention includes the above-mentioned control system, it also has the advantages of the above-mentioned control system, and the overall structure is simple and easy to implement.
  • Figure 1 is a flow chart of the liquid medicine filling control method of the present invention.
  • Figure 2 is a schematic diagram of the structure of the liquid medicine filling system of the present invention.
  • the liquid medicine filling control system of this embodiment includes a control unit 6 and a flow sensor 4; the control unit 6 is connected to the flow sensor 4; the flow sensor 4 is used to detect the medicine in the filling pipeline 2 in real time. Liquid flow rate or liquid liquid volume; the control unit 6 is used to obtain the actual filling volume L1 of a single filling of the medicine bottle according to the liquid medicine flow or volume, so as to control the single filling stroke of the filling pump 3 (such as the filling pump The number of revolutions and angles of a single filling of the servo motor are calibrated to form a closed loop control.
  • the flow sensor 4 is not affected by the surrounding environment during measurement, does not require additional auxiliary devices, has a simple structure, saves costs, and is very convenient for installation and debugging, which improves labor productivity;
  • the flow rate of the liquid medicine in the filling pipeline 2 is detected in real time to obtain the actual single filling volume L1 corresponding to the medicine bottle 5. That is, the detection process and the filling process are synchronized to avoid the need to add other items before and after the filling in the weighing link. Process, thereby improving the efficiency of the entire filling; and the overall structure is simple and easy to implement.
  • the liquid medicine filling control system of the present invention detects the liquid medicine flow rate or liquid medicine volume in the filling pipe 2 through the flow sensor 4, and directly obtains the actual filling amount L1, without the need to adopt the quality and volume required in the weighing link.
  • the conversion of density, etc. reduces uncertainties and improves the accuracy of calibration.
  • the liquid medicine filling control system of the present invention adopts a completely different idea from the method of weighing before and after filling the medicine bottle to obtain the actual filling amount L1, that is, the medicine entering the medicine bottle on the filling pipeline 2 is directly measured by the flow sensor 4
  • the liquid flow is directly detected to obtain the actual filling volume L1 each time, and then feedback to the control unit according to the actual filling volume L1 to realize the closed-loop control of the filling pump 3, thereby improving the filling accuracy and reducing the filling volume. Qualified risk.
  • the difference A between the two is obtained according to the preset target filling volume L and the actual filling volume L1, and then the filling servo motor in the filling pump 3 is filled according to the difference A.
  • Filling stroke calibration in which the filling stroke is the number of revolutions or angles corresponding to each filling of the medicine bottle. During the initial filling, it is preset according to the size of the medicine bottle and the filling speed of the liquid medicine.
  • the flow sensor 4 is a non-contact high-precision ultrasonic sensor, which is clamped at any position of the filling pipeline 2 (connecting the filling pump 3 and the filling head 7) by a clamp; the installation structure is simple and the disassembly is simple. Easy to install and low cost.
  • the control unit 6 is a PLC controller.
  • the present invention also discloses a liquid medicine filling system, which includes a liquid reservoir 1, a filling pump 3, a filling head 7 and the liquid medicine filling control system as described above; a filling pump 3
  • the input end of the filling pump 3 is connected to the reservoir 1
  • the output end of the filling pump 3 is connected to the filling head 7 through the filling pipe 2
  • the control end of the filling pump 3 is connected to the control unit 6 in the liquid medicine filling control system.
  • the output terminal is connected. Since the liquid medicine filling system of the present invention includes the above control system, it also has the advantages of the above control system, and the overall structure is simple and easy to implement.
  • the liquid medicine filling control method of this embodiment includes the following steps:
  • the liquid medicine filling control method of the present invention also has the advantages of the above control system, and the operation is simple and convenient.
  • step S05 when the average deviation ⁇ A is greater than the preset allowable filling amount deviation range a%, the single filling stroke of the filling pump 3 is calibrated, otherwise it is not calibrated.
  • a% ⁇ b% when calibrating, according to the average deviation ⁇ A, the number of revolutions of the filling pump servo motor for a single filling is proportionally adjusted, and the proportional relationship between the two is preset before.
  • step S04 the average deviation ⁇ A is obtained by averaging the N differences A; in other embodiments, after removing a maximum value and a minimum value, the average deviation ⁇ A can be obtained by averaging. the way.
  • step S01 the non-contact high-precision liquid flow sensor 4 installed on the filling pipe 2 is used to detect the flow of the liquid medicine in the filling pipe 2 in real time.
  • the flow and quality of the liquid in the pipeline 2 have no effect and meet the requirements of GMP.
  • the high-precision flow sensor 4 is fastened to the filling pipeline 2 and does not contact the liquid medicine; the PLC controller communicates with each filling pump 3 and each high-precision flow sensor 4 through a communication cable.
  • the PLC controller drives the quantitative filling pump 3 to extract a certain amount of liquid medicine from the reservoir 1, and sends it into the medicine bottle 5 through the filling pipe 2.
  • the PLC controller sends a signal to the high-precision flow sensor 4Start measurement.
  • the PLC controller sends a signal to the high-precision flow sensor 4 to end the measurement; the high-precision flow sensor 4 performs calculations when receiving the end signal, and returns the flow value obtained within T to the PLC control If the preset target filling volume is L, the PLC controller will compare the actual filling volume L1 with the preset target filling volume L to obtain the filling volume deviation A .
  • the high-precision flow sensor 4 give the high-precision flow sensor 4 a set value before filling.
  • the PLC controller sends a signal to the high-precision flow sensor 4 to start measuring.
  • the high-precision flow sensor 4 After the time T, when the high-precision flow sensor 4 first detects the When the loading volume is reached, the high-precision flow sensor 4 sends a signal to the PLC controller, and the PLC controller sends a stop signal, and automatically calculates the negative deviation A of the loading volume.
  • the allowable filling volume deviation range is a% and the limit filling volume deviation range is b% according to the technological requirements of the chemical liquid, when A ⁇ b, the cumulative filling number K; the above parameters are described as follows:
  • b% is the allowable limit deviation range value of the liquid medicine filling, and the filling quantity error exceeds this range, the medicine is unqualified;
  • a% is a set value less than b%, which is the pre-calibrated value set by the PLC controller. When the filling error exceeds this value, the PLC controller needs to calibrate the filling pump 3.
  • the PLC controller will install Calibration calculation to obtain the average deviation ⁇ A of N times deviation A (for example, after summing the deviation A of 5 times, divide it by 5).
  • the PLC controller resets the number of revolutions (or angle and other filling strokes) of the filling pump 3 servo drive motor in a single filling cycle according to the average deviation ⁇ A to control quantitative filling Install the servo drive motor of pump 3 to calibrate the volume.
  • the difference A is greater than a% but less than b%, the drug loading is actually qualified; if A>b%, the PLC controller determines that there is an abnormal loading, and the PLC controller will alarm and stop, and prompt the drug Unqualified filling volume and possible filling abnormalities.
  • the high-precision flow sensor of the present invention is not affected by the surrounding environment during measurement, does not require additional auxiliary devices, has a simple structure, saves costs, and is very convenient to install and debug, which improves labor productivity; in addition, the high-precision flow sensor measures filling in real time
  • the filling volume of the pump and the liquid medicine filling are carried out at the same time, without waiting time, greatly improving production efficiency, realizing 100% metering and real-time calibration, effectively preventing the occurrence of unqualified filling volume.
  • the volume of the liquid medicine flowing through the pipeline is directly measured by the high-precision flow sensor, without conversion, and the uncertainty caused by weighing is avoided in principle.

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Abstract

一种药液灌装***、控制***及方法，包括贮液器、灌装泵、灌装头、控制单元和流量传感器；灌装泵与贮液器相连，灌装头通过灌装管路与灌装泵相连，流量传感器用于实时检测药液流量或体积；控制单元用于根据药液流量或体积得到实际装量L1以对灌装泵的灌装行程进行校准。在灌装时检测药液流量，得到药瓶实际装量L1，再得到预设目标装量L与L1之间的差值A；通过差值A对灌装泵单次灌装行程进行校准。该药液灌装***、灌装控制***及方法均具有灌装精度高、效率高等优点。

Description

一种药液灌装控制***、灌装***及控制方法 技术领域
本发明主要涉及医药、食品包装技术领域，特指一种药液灌装控制***、灌装***及控制方法。
背景技术
目前制药行业中，药液灌装通常是采用容积泵，针对药液装量的计量和校准，普遍采用的是通过灌装前后的药瓶称重来获取药液的质量，再经密度换算成体积装量的方法来获取药瓶的实际装量，然后将获取的实际装量与设定装量进行对比，根据两者的差值实现校准。如专利文献CN102460091B中公开了：采用第一称重装置对空容器的进行称重，采用第二称重装置对填充有产品的容器进行称重，从而实现对药品的计量。此类计量和校准的方法及结构存在以下问题：
1、成本较高
由于称重***对环境要求、安装精度要求非常高，且自身的结构复杂，制造成本高，安装调试比较麻烦，同时辅助装置较多，包括去静电装置、减震装置、称重通道及驱动装置等等，因此整套称重***的综合成本非常高。如专利文献CN102460091B中的第一称重装置、第二称重装置的本身结构以及相关的传送装置结构复杂，且成本较高。
2、生产效率低，有发生装量不合格的风险
采用称重***校验灌装泵的装量时，先要对空瓶进行称重，灌装后再称重，且称重达到稳态需要一定的时间。因此运行称重***需要占用大量的生产时间，设备产能大打折扣，降低生产效率，在保证产能的前提下，采用称重***校验灌装泵的装量时，只能采取抽样称重进行校准，有产生不合格品药品的风险。如专利文献CN102460091B中的需要对空瓶和填充后的瓶子分别进行称重，不仅影响了灌装效率，同时也影响了输送效率。
3、获取的装量不准确
根据装量(V)、密度(ρ)和质量(m)的关系V＝m/ρ可知，装量V的准确性依赖于药液的质量和密度。但是第一，药品的成分复杂，且很多药液是在灌装前进行混合的，因而难以获得药液的准确密度；第二，用于药液称重的高精度电子称本身的精度虽然较高，但这种电子 称同时对环境要求也非常高，如机器的震动、百级层流风、周围的磁场、药液灌装过程中产生的静电等都会影响称重的精度。以上两方面的因素导致装量的准确性也无法保证。
发明内容
本发明要解决的技术问题就在于：针对现有技术存在的技术问题，本发明提供一种灌装精度及效率高、以及结构简单的灌装控制***及灌装***，并相应提供一种灌装精度及效率高的药液灌装控制方法。
为解决上述技术问题，本发明提出的技术方案为：
一种药液灌装控制***，包括控制单元和流量传感器；所述控制单元与所述流量传感器相连；所述流量传感器用于实时检测连接灌装泵与灌装头的灌装管路中的药液流量或药液体积；所述控制单元用于根据药液流量或药液体积得到药瓶单次灌装的实际装量L1，以对灌装泵的单次灌装行程进行校准以形成闭环控制。
作为上述技术方案的进一步改进：
所述流量传感器为非接触式的超声波传感器。
所述流量传感器通过卡箍紧固于所述灌装管路上。
本发明还公开了一种药液灌装***，包括贮液器、灌装泵和灌装头，还包括如上所述的药液灌装控制***；所述灌装泵的输入端与所述贮液器相连通，所述灌装泵的输出端通过灌装管路与所述灌装头相连通，所述灌装泵的控制端与所述药液灌装控制***中控制单元的输出端相连。
本发明还公开了一种药液灌装控制方法，包括步骤：
S01、在灌装的过程中，实时检测灌装管路中的药液流量；
S02、在药瓶灌装完成后，通过灌装过程中的药液流量得到药瓶对应的实际装量L1，再得到预设目标装量L与实际装量L1之间的差值A；
S03、当差值A小于极限装量偏差b％时，对灌装次数K进行累计；
S04、当K累计等于预设次数N时，通过N个差值A得到平均偏差ΔA，其中N为非零的自然数；
S05、根据平均偏差ΔA对灌装泵的单次灌装行程进行校准。
作为上述技术方案的进一步改进：
在步骤S05中，当平均偏差ΔA大于预设允许装量偏差范围a％时，则对灌装泵的单次灌装行程进行校准，否则不校准。
在步骤S03中，当差值A不小于极限装量偏差b％时，则判断药品不合格，并报警停机。
1≤N≤10。
在步骤S04中，通过N个差值A求平均得到平均偏差ΔA；或者去掉一个最大值和一个最小值后，再求平均得到平均偏差ΔA。
在步骤S01中，通过安装于灌装管路上的非接触式液体流量传感器实时检测灌装管路中的药液流量。
与现有技术相比，本发明的优点在于：
本发明的药液灌装控制***，流量传感器在测量时不受周边环境的影响，无需额外的辅助装置，结构简单，节约了成本，同时安装调试非常方便，提高了劳动生产率；在灌装过程中实时检测灌装管路中的药液流量以得到药瓶对应的单次实际装量L1，即检测过程与灌装过程同步进行，避免类似称重环节中需要在灌装前后增加其它工序，从而提高了整个灌装效率；而且整体结构简单且易于实现。
本发明的药液灌装控制***，采用了与药瓶灌装前后称重以得到实际装量L1方式完全不同的思路，而是通过流量传感器对灌装管路上进入药瓶的药液流量或体积进行直接检测，从而得到每次的实际装量L1，再根据实际装量L1反馈至控制单元中，实现对灌装泵的闭环控制，从而提高灌装的精度，降低了装量不合格的风险。
本发明的药液灌装控制***，由于通过流量传感器检测灌装管路中的药液流量或药液体积，直接得到实际装量L1，无需要采用称重环节中所需要的质量、密度等换算，减少了不确定因素，提高了校准的精度。
本发明的药液灌装控制方法，同样具有如上控制***所述的优点。
本发明的药液灌装***，由于包括上述控制***，同样具有如上控制***所述的优点，而且整体结构简单且易于实现。
附图说明
图1为本发明的药液灌装控制方法流程图。
图2为本发明的药液灌装***结构示意图。
图中标号表示：1、贮液器；2、灌装管路；3、灌装泵；4、流量传感器、5、药瓶；6、控制单元；7、灌装头。
具体实施方式
以下结合说明书附图和具体实施例对本发明作进一步描述。
如图1所示，本实施例的药液灌装控制***，包括控制单元6和流量传感器4；控制单元6与流量传感器4相连；流量传感器4用于实时检测灌装管路2中的药液流量或药液体积；控制单元6用于根据药液流量或药液体积得到药瓶单次灌装的实际装量L1，以对灌装泵3的单次灌装行程(如灌装泵伺服电机单次灌装的转数、角度等)进行校准以形成闭环控制。
本发明的药液灌装控制***，流量传感器4在测量时不受周边环境的影响，无需额外的辅助装置，结构简单，节约了成本，同时安装调试非常方便，提高了劳动生产率；在灌装过程中实时检测灌装管路2中的药液流量以得到药瓶5对应的单次实际装量L1，即检测过程与灌装过程同步进行，避免称重环节中需要在灌装前后增加其它工序，从而提高了整个灌装的效率；而且整体结构简单且易于实现。
本发明的药液灌装控制***，由于通过流量传感器4检测灌装管路2中的药液流量或药液体积，直接得到实际装量L1，无需要采用称重环节中所需要的质量、密度等换算，减少了不确定因素，提高了校准的精度。
本发明的药液灌装控制***，采用了与药瓶灌装前后称重以得到实际装量L1方式完全不同的思路，即直接通过流量传感器4对灌装管路2上进入药瓶的药液流量进行直接检测，从而得到每次的实际装量L1，再根据实际装量L1反馈至控制单元中，实现对灌装泵3的闭环控制，从而提高灌装的精度，降低了装量不合格的风险。
具体地，在进行闭环控制时，先根据预设目标装量L与实际装量L1，得到两者之间的差值A，再根据差值A进行灌装泵3中灌装伺服电机的灌装行程校准，其中灌装行程为药瓶每次灌装所对应的转数或角度等，在初始灌装时，根据药瓶规格大小、药液灌装速度等进行预设。
本实施例中，流量传感器4为非接触式的高精度超声波传感器，通过卡箍卡固于灌装管路2(连通灌装泵3与灌装头7)的任意位置；安装结构简单、拆装简便且成本较低。控制单元6为PLC控制器。
如图1所示，本发明还公开了一种药液灌装***，包括贮液器1、灌装泵3、灌装头7以及如上所述的药液灌装控制***；灌装泵3的输入端与贮液器1相连，灌装泵3的输出端通过灌装管路2与灌装头7相连，灌装泵3的控制端与所述药液灌装控制***中控制单元6的输出端相连。本发明的药液灌装***由于包括上述控制***，同样具有如上控制***所述的优点，而且整体结构简单且易于实现。
如图2所示，本实施例的药液灌装控制方法，包括步骤：
S01、在药液灌装***中的灌装泵3向药瓶5进行灌装的过程中，实时检测灌装管路2中的药液流量；
S02、在单个药瓶5灌装完成后，通过灌装过程中的药液流量得到药瓶5对应的单次实际装量L1，再得到预设目标装量L与实际装量L1之间的差值A，A＝L-L1；
S03、当差值A小于极限装量偏差b％时，对灌装次数K进行累计，如差值A不小于极限装量偏差b％时，则判断药品装量不合格，并报警停机；
S04、当K累计等于预设次数N(非零自然数)时，通过N个差值A得到平均偏差ΔA；
S05、根据平均偏差ΔA对灌装泵3的单次灌装行程(如灌装泵伺服电机单次灌装的转数、角度等)进行校准。
本发明的药液灌装控制方法，同样具有如上控制***所述的优点，而且操作简便。
本实施例中，在步骤S05中，当平均偏差ΔA大于预设允许装量偏差范围a％时，则对灌装泵3的单次灌装行程进行校准，否则不校准。其中a％＜b％；在进行校准时，根据平均偏差ΔA值对灌装泵伺服电机单次灌装的转数进行比例调整，两者之间的比例关系在之前进行预设。
本实施例中，在步骤S04中，通过N个差值A求平均得到平均偏差ΔA；在其它实施例中，也可以采用去掉一个最大值和一个最小值后，再求平均得到平均偏差ΔA等方式。
本实施例中，在步骤S01中，通过安装于灌装管路2上的非接触式的高精度液体流量传感器4实时检测灌装管路2中的药液流量，检测精度高且对灌装管路2中的液体流动及质量无影响，满足GMP的要求。
现结合本发明的药液灌装***与药液灌装控制方法，对其整个灌装过程做具体说明：
高精度流量传感器4卡固在灌装管路2上，不与药液接触；PLC控制器通过通信线缆分别与各个灌装泵3和各个高精度流量传感器4进行通讯。
灌装开始时，PLC控制器驱动定量灌装泵3从贮液器1抽取一定量的药液，经灌装管路2送入药瓶5中，同时PLC控制器发送信号给高精度流量传感器4开始测量。经过时间T，单次灌装完成，PLC控制器发送信号给高精度流量传感器4结束测量；高精度流量传感器4在接收到结束信号时，进行运算，将T时间内获得流量值返回给PLC控制器(即视为单次灌装的实际装量L1)，若预设目标装量值为L，PLC控制器将获得实际装量L1与预设目标装量L进行比较，得到装量偏差A。
另外，在灌装前给高精度流量传感器4一个设定值，灌装开始时，PLC控制器发送信号给高精度流量传感器4开始测量，经过时间T，当高精度流量传感器4先行检测到已达到装量设定值时，高精度流量传感器4将信号传送给PLC控制器，PLC控制器发出停止信号，并自动计算装量负偏差A。
若根据药液的工艺要求预设允许装量偏差范围为a％，极限装量偏差范围为b％，则当A≤b时，累积装量次数K；对以上参数进行说明如下：
(1)b％为药液灌装允许的极限偏差范围值，装量误差超出该范围则为药品不合格；
(2)a％为设定的小于b％的某个值，是PLC控制器设置的提前校准的值，当装量误差超过这个值时PLC控制器需要对灌装泵3进行校准。
若设定装量N次(优选在1～10中进行选择，可根据实际情况进行选择)后，需要对装量进行校准，则当K＝N(如5次)时，PLC控制器进行装量校准计算，得到N次偏差A的平均偏差ΔA(如5次偏差A求和后，再除以5)。当平均偏差ΔA大于a％，PLC控制器则根据平均偏差ΔA重新设定灌装泵3伺服驱动电机在单次灌装周期的转数(或角度等灌装行程)，以此来控制定量灌装泵3的伺服驱动电机进行装量校准。其中差值A大于a％而小于b％时，药品装量实际上是合格的；若A>b％时，则PLC控制器判断为出现异常装量，PLC控制器进行报警停机，并提示药品装量不合格和可能出现灌装异常的情况。
本发明的高精度流量传感器在测量时不受周边环境的影响，无需额外的辅助装置，结构简单，节约了成本，同时安装调试非常方便，提高了劳动生产率；另外高精度流量传感器实时测量灌装泵的灌装量，与药液灌装是同时进行的，无需等待时间，大大提高了生产效率，可实现100％计量和实时校准，有效防止了装量不合格现象的发生。通过高精度流量传感器直接测量药液流经管道的体积，无需换算，从原理上避免了称重带来的不确定因素。
虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发明。任何熟悉本领域的技术人员，在不脱离本发明技术方案范围的情况下，都可利用上述揭示的技术内容对本发明技术方案做出许多可能的变动和修饰，或修改为等同变化的等效实施例。因此，凡是未脱离本发明技术方案的内容，依据本发明技术实质对以上实施例所做的任何简单修改、等同变化及修饰，均应落在本发明技术方案保护的范围内。

Claims (10)

  1. 一种药液灌装控制***，其特征在于，包括控制单元(6)和流量传感器(4)；所述控制单元(6)与所述流量传感器(4)相连；所述流量传感器(4)用于实时检测连接灌装泵(3)与灌装头(7)的灌装管路(2)中的药液流量或药液体积；所述控制单元(6)用于根据药液流量或药液体积得到药瓶(5)单次灌装的实际装量L1，以对灌装泵(3)的单次灌装行程进行校准以形成闭环控制。
  2. 根据权利要求1所述的药液灌装控制***，其特征在于，所述流量传感器(4)为非接触式的超声波传感器。
  3. 根据权利要求2所述的药液灌装控制***，其特征在于，所述流量传感器(4)通过卡箍紧固于所述灌装管路(2)上。
  4. 一种药液灌装***，包括贮液器(1)、灌装泵(3)和灌装头(7)，其特征在于，还包括如权利要求1或2或3所述的药液灌装控制***；所述灌装泵(3)的输入端与所述贮液器(1)相连通，所述灌装泵(3)的输出端通过灌装管路(2)与所述灌装头(7)相连通，所述灌装泵(3)的控制端与所述药液灌装控制***中控制单元(6)的输出端相连。
  5. 一种药液灌装控制方法，其特征在于，包括步骤：
    S01、在灌装的过程中，实时检测灌装管路(2)中的药液流量；
    S02、在灌装完成后，通过灌装过程中的药液流量得到药瓶(5)对应的实际装量L1，再得到预设目标装量L与实际装量L1之间的差值A；
    S03、当差值A小于极限装量偏差b％时，对灌装次数K进行累计；
    S04、当K累计等于预设次数N时，通过N个差值A得到平均偏差ΔA，其中N为非零的自然数；
    S05、根据平均偏差ΔA对灌装泵(3)的单次灌装行程进行校准。
  6. 根据权利要求5所述的药液灌装控制方法，其特征在于，在步骤S05中，当平均偏差ΔA大于预设允许装量偏差范围a％时，则对灌装泵(3)的单次灌装行程进行校准，否则不校准。
  7. 根据权利要求6所述的药液灌装控制方法，其特征在于，在步骤S03中，当差值A不小于极限装量偏差b％时，则判断药品不合格，并报警停机。
  8. 根据权利要求5或6或7所述的药液灌装控制方法，其特征在于，1≤N≤10。
  9. 根据权利要求5或6或7所述的药液灌装控制方法，其特征在于，在步骤S04中，通过N个差值A求平均得到平均偏差ΔA；或者去掉一个最大值和一个最小值后，再求平均得到平均偏差ΔA。
  10. 根据权利要求5或6或7所述的药液灌装控制方法，其特征在于，在步骤S01中，通过安装于灌装管路(2)上的非接触式液体流量传感器(4)实时检测灌装管路(2)中的药液流量。
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