Labor automation under control

Small build space, large stroke – the small parts gripper GEP2000 can be individually adapted, such as here with a sealed gripping module in hygienic design.

Handling of vials with the GEP2000 gripper from Zimmer Group.

A combination of the GEP2000 gripper and a rotary module enables automated de- and recapping.

The aseptic tool changer is a standard product from the Zimmer Group for use in particularly hygienic areas.

In hardly any other industry are the requirements for automation technology as high as in medical device manufacturing environments. To prevent contamination of pharmaceutical and medical products as well as production disruptions, it is essential to minimize particle emissions and implement enhanced hygiene measures. This also applies to handling technology, which in laboratories and medical device production must create the framework conditions for safe and clean processes and cleaning. The automation specialist Zimmer Group meets these requirements with handling solutions that combine precision, reliability, and hygiene standards.

Requirements in Medical Technology Environments

The production of high-quality products in the healthcare sector places special demands on safety and hygiene. This concerns both manufacturing technology and handling components. Hygienic design and durable materials such as stainless steel ensure easy cleaning and longevity under demanding conditions. The sealing of the components is indicated by the IP protection class. For use in the medical-pharmaceutical field, particle emission is also critical. In pharmaceuticals, cleanroom classes with reduced particle release according to GMP and DIN EN ISO 14644 apply. Strict guidelines regulate the materials and lubricants used, including FDA regulation 21 CFR 178.3570 and the FDA material list for medical devices.

What do these production parameters mean for the selection of the gripper? Pneumatic grippers are not suitable in medical-pharmaceutical environments because compressed air operation inevitably leads to increased particle emissions, thus not guaranteeing a particle-free ambient air and clinical cleanliness. Therefore, electric grippers are the preferred choice, offering additional advantages over pneumatically operated grippers besides reduced particle emissions.

Safe Handling of Fragile Workpieces

The Zimmer Group has developed the GEP2000 series, a small parts gripper specifically designed for use under increased hygiene requirements and in cleanrooms. The electric gripper is standard equipped with splash water and dirt protection according to protection class IP 54. Thanks to food-grade H1 lubricant, it is suitable for use in pharmaceutical and medical technology as well as in the food industry. Stainless steel covers and screws protect against corrosion and make cleaning particularly user-friendly. Low particle emissions also enable certification for cleanroom class 2.

The GEP2000 series grippers are used, for example, in handling fragile objects. For a customer in the pharmaceutical industry, Zimmer Group equipped a filling system with these electric grippers, enabling safe handling of vials and syringes. The small parts gripper impresses in this application with its compact size and large stroke. For this application, the stroke was increased to 11 mm.

According to the basic principles of hygienic design, the surfaces are made of stainless steel and PEEK, making them resistant to aggressive cleaning agents. Additionally, the electronics' sealing was increased to IP 65. The standard mechanical self-locking ensures a secure hold of the workpiece even in the event of a power failure or emergency stop. This prevents, for example, infectious sample containers from falling and contaminating entire laboratory areas. The emergency release allows manual opening of the gripper in such cases, even without power to the machine.

Electric Gripper with Intelligent Feature

To reliably recognize and securely grip different products, the GEP2000 series features integrated position detection. The automatic part recognition provides an additional quality assurance in the process. Default values can be stored for workpieces, including tolerances, in the gripper. The integrated automatic part recognition immediately detects deviations in the product from the gripper, allowing for immediate sorting. The small parts gripper is available in Digital I/O and IO-Link variants. The latter enables particularly comfortable control and connection to the system.

Automation of Complex Handling Tasks

Pure gripping technology is not always sufficient in laboratory automation; many handling tasks in the lab are more complex. A typical example is screwing on and off sample tubes.

To solve such tasks, Zimmer Group combined a GEP2000 series gripper with a rotary module for a customer. The combination of rotation and gripping is used, for example, as a decapper and recapper for sample tubes. It can also be used for labeling bottles or positioning barcodes on sample tubes for scanning. The forces and positions of the gripper and rotary module are individually adjustable. This allows various container sizes to be handled individually and at high process speeds.

Robotics for Cleanrooms

Not only the end effectors but also robotics must meet the requirements of the laboratory. Therefore, Zimmer Group has now added a tool changer to its standard portfolio that meets hygienic design requirements. It is made of PEEK (Polyetheretherketone) and features cable glands and sealing caps made of PTFE. The sealing of the changer complies with protection class IP67, thus also protecting against water ingress. All openings, including spring pins and connection cables, are securely sealed. The high-quality material also allows reliable cleaning with H2O2 without damaging the surface of the changer.

Depending on the robot's payload, handling weight can be up to ten kilograms. The tool changer has multiple spring pins that ensure the transmission of various signals and currents. An integrated coding switch allows differentiation of up to seven different workpieces.

An outstanding safety feature of the changer is its permanent electromagnet, which not only enables magnetic switching of the latch but also securely fixes the tool and workpiece even in a de-energized state—such as during emergency stop or power failure. This ensures a safe process. Additionally, the rotation lock ensures rotational alignment between the fixed and moving parts and reliably transmits the necessary torque.

The Zimmer Group, with over 1,300 employees and a sales network in 125 countries, is one of the world's leading specialists in handling and automation technology. The company offers a wide range of components that meet the highest requirements for particle emission and hygiene safety. For example, more than 500 products are cleanroom certified. In addition to an extensive standard portfolio, Zimmer Group offers demanding custom solutions for companies in the medical and pharmaceutical industries, as well as other sectors.