The Automated Sampling Tube Filling and Capping Monoblock integrates tube unscrambling, precision dosing, and servo capping into a unified platform, with an optional horizontal wrap-around labeling module. Engineered for industrial-scale packaging of 2–20 mL sampling vials and diagnostic tubes, the system achieves stable production speeds of 50–70 tubes/min. Dosing is driven by high-purity ceramic plunger pumps or peristaltic pumps, regulated by an integrated PLC and touchscreen HMI with real-time sensory diagnostics.
Operating Workflow & Motion Sequence
Tube Unscrambling & Alignment: A reciprocating push-plate hopper organizes bulk, randomized tubes into parallel guide tracks.
Servo Pick-and-Place Infeed: Dual servo-driven mechanical grippers transfer two tubes per cycle, placing them into dedicated rotary pucks.
Indexing Transfer: A precision starwheel dial indexes the fixtures synchronously through downstream stations.
Diving Liquid Dosing: Dual-head diving nozzles, driven by ceramic plunger or peristaltic pumps, deliver 2–20 mL fills with a dosing accuracy within ±2% (for standard 6–12 mL volumes).
Cap Sorting & Pre-Threading: A vibratory bowl aligns caps while dual servo mechanical arms pick, orient, and pre-thread the caps onto the vial necks.
Servo-Controlled Capping: Dual servo torquing chucks fasten the caps to target torque values configured and monitored via the HMI.
Discharge & Transfer: Dual mechanical grippers extract finished tubes and route them through an exit chute toward downstream sorting or labeling.
Optional In-Line Labeling: A horizontal wrap-around labeling station applies opaque pressure-sensitive labels with an accuracy of ±0.5 mm at speeds exceeding 70 tubes/min.
Safety Interlocks & Sensory Monitoring
Infeed Verification: Automatic alarm triggers if the sorting chute runs low or if a pick cycle detects a missing tube.
Process Interlocking: Dynamic "No tube – No fill / No cap / No label" logic prevents product waste and equipment fouling.
Actuator Stroke Diagnostics: Real-time position feedback monitors pneumatic cylinder stroke limits and robotic manipulator paths.
Downstream Integration: The monoblock pauses automatically if a downstream labeling jam occurs, and signals halts upon missing labels or ribbon exhaustion.
Technical Specifications
Baseline Parameters
Working Heads: Dual-channel synchronous architecture (2-head infeed, filling, pre-threading, and capping).
Vial Compatibility: Accommodates cylindrical vials via modular tooling. Hansheng Automation designs and precision-machines custom indexing starwheels and tube-holding nests tailored to customer-supplied container geometries, ensuring scratch-free handling and rapid line changeovers.
Discharge Height: 750 mm ± 25 mm.
Utility Requirements: ~3 kW; 220V AC single-phase; compressed air: 0.6–0.8 MPa at 300 L/min.
Core Mechanical & Control Units
Dispensing Unit: Dive-in filling assembly coupled with ceramic plunger pumps or peristaltic metering systems.
Torquing Mechanism: Dual servo capping spindles with digital torque setting and peak-torque monitoring on the HMI.
Pick-and-Place: Dual pneumatic parallel grippers with servo horizontal indexing.
Control Platform: Xinje PLC with a 7-inch color graphic touchscreen.
Material & Component Construction
Structural Frame: Built with SUS304 stainless steel; exposed components are manufactured from hard-anodized aluminum alloy, passivated stainless steel, electroless nickel-plated 45# steel, and POM engineering polymers.
Pneumatics: AirTAC pneumatic actuators and directional solenoid valves.
Sensors: Photoelectric and fiber-optic detection array from Leuze, Panasonic, or Omron.
Electrical Switchgear: Schneider Electric circuit breakers, contactors, and relays.
Drives: Delta variable-frequency motor drives paired with Xinje servo motion controllers.
Optional Module: Horizontal Roll-On Labeling Machine
Technical Parameters
Applicable Vial Dimensions: Diameter φ15–φ30 mm; length 20–120 mm.
Label Dimensions: Width 10–80 mm; length 10–100 mm (opaque labels).
Labeling Mechanism: Horizontal roller bed with high-friction wrapping belt (accuracy: ±0.5 mm; throughput: ≥ 70 tubes/min).
Conveyor: Chain-driven nylon roller conveyor with an adjustable working height of 750 mm ± 25 mm.
Power & Control: 850 W / 220V single-phase, operated via dedicated Samkoon PLC and touchscreen.
To support diverse non-standard packaging applications, we provide precision CNC machining for core mechanical fixtures, gripper fingers, and custom mounting brackets to match customer-specific tube configurations.
