AN ELECTROMAGNETIC MOVER SYSTEM FOR HANDLING CAPSULES IN A CAPSULE-FILLING MANUFACTURING UNIT

Abstract

The present disclosure relates to an electromagnetic mover system (115) for handling capsules in a capsule-filling manufacturing unit 100. The electromagnetic mover system (115) includes at least one magnetic mover (102), an elevated support structure (106) attached to the magnetic mover (102), a body plate (108) adapted to hold a plurality of capsule bodies and at least one body engagement plate (112) adapted to be positioned underneath the body plate (108) and to be engaged with each capsule body (208). The body plate (108) is disposed on the elevated support structure (106) such that an open end of the channel (209) faces a gap (116) and each capsule body (208) is accessible through the gap (116). The body engagement plate (112) is adapted to be positioned in the gap (116) such that the body engagement plate (112) accesses each capsule body (208) via the channel (209).

Specification

Description:FIELD OF THE INVENTION

The present disclosure generally relates to a capsule-filling manufacturing unit, and more particularly, an electromagnetic mover system for handling capsules in the capsule-filling manufacturing unit.

BACKGROUND

Modern capsule-filling manufacturing involves high speed production on rotary and linear indexing machines that has not evolved in decades. The process of capsule filling is carried out in a linear environment involving multiple production stations with differing cycle times, limited modularity, limited flexibility, prone to entire line stoppages, long and complex batch changeouts and with almost no integration with packaging. Traditional capsule-filling manufacturing makes use of a 'single drive' approach where each index in a production line is fixed and dependent upon the indexing of processes ahead and behind. This methodology of indexing does not allow for production steps to operate independent of one another. It may be locked "in-step" with the rest of the production activities, largely inflexible and unable to optimize individual processes or flex with changing production criteria.

The current state of the art in capsule-filling manufacturing units incorporate a series of independent activities. These activities are run continuously in series, using a variety of different operations such as capsule loading, capsule splitting, capsule capping, and capsule ejection. The operations are usually carried out on large-scale, high volume equipment that is highly integrated between the various operations. Further, the operations are often carried in large physical spaces located proximately or distant from one another utilizing linear and/or circuitous, intermittent, or continuous processes that are incapable of modification or flexibility. Thus, the capsule-filling manufacturing needs to evolve to better leverage modern manufacturing technologies and trends that are capable of modular production, flexibility, rapid batch, and parts changeover, is better equipped to deal with quality issues, routing, and downstream integration.

Conventionally, in a capsule-filling manufacturing unit, traditional production lines such as a sequential manufacturing processes set out in engineering design are employed. The sequential manufacturing processes are highly inefficient when dealing with production involving many co-dependent activities with lengthier times, where conditioning or dwelling are required. The sequential manufacturing process limits production output by the slowest cycle/process time. The major limitations of the sequential manufacturing process are as follows. Firstly, the sequential production process is severely hampered by the impact of production breakdowns and product failure. Any stoppage on any part of the line generally stops all production activities. Secondly, the sequential production process has challenges integrating with separate in-feed and out-feed lines especially in cases where those lines operate in a differing speed. Thirdly, the sequential production process suffers from a major lack of modularity, making the addition of functional stations and secondary processing impossible as well as making product, and batch changeover challenging. Fourthly, lack of modularity also limits manufacturer's ability to speed up production by adding additional production stations. Fifthly, the sequential production process is unable to buffer production to better account for stoppages or slowed production processes and in many cases product needs to be stockpiled "off-line" in order to be able to be introduced into the line when complete.

The traditional manufacturing process and architecture in the capsule-filling manufacturing has not been through any major change, mainly due to the complexity and inaccuracy of alternative systems. However, in recent times there has been a major change in production architecture resulting in a Contactless Electromagnetic Manufacturing system (CEMS). The changes may be attributed to firstly, development in contactless movement equipment making use of electromagnetic technologies. Secondly, development of locational accuracy in electromagnetic systems. Thirdly, development in power and speed of systems to accurately move and control electromagnetic systems. Fourthly, development in power and speed of information systems in individual tracking, scheduling, stacking, production and control over multiple movers in an electromagnetic system.

Presently, the Contactless Electromagnetic Manufacturing systems (CEMS) making use of electromagnetic technologies promises a viable alternative to the sequential manufacturing process in the capsule-filling manufacturing unit. The CEMS allows for highly accurate and free movement of carrier plates holding product. The movement of the carrier plates or movers allows the product to dynamically move through the production process. Further, the CEMS provides for modular scaling of production by adding or removing production stations. The modularity allows user to increase stations with slow indexing times, thereby optimizing production cycle times and significant improvement in production output. Further, the CEMS provides for the ability to infeed and outfeed between production lines and sub production areas with smart and efficient scheduling. The CEMS further provides the ability to dynamically route product in the manufacturing process according to real time availability of production stations, maximizing production output and utilization. The CEMS further provides for the ability to stack products in manufacturing process dynamically within the production area, thereby ensuring quantities of buffer items which ensure that there is no production waiting times and maximum efficiency. Furthermore, the CEMS provides for the ability to stack products in progress in the event of stoppages, cleaning or maintenance without stopping upstream processes. Also, the CEMS provides for the ability to change out batches quickly by only replacing certain modular stations. Moreover, the CEMS enable to route products in manufacturing process, finished products, packaging and other manufacturing inputs along any route. Further, the CEMS may also allow for modified production processes allowing typically complex and integrated production processes to be broken down into smaller more discrete processes that no longer require consolidation.

The Contactless Electromagnetic Manufacturing Systems employ magnetic movers that that are levitated above a manufacturing plane. The movers are contactless and flexible able to achieve significant manufacturing efficiency through dynamic routing, stacking, and independent travel, thereby achieving substantial optimization of manufacturing processes as well as accommodating rework, blockages and other optimization strategies. However, CEMS in its current configuration have severe restrictions in its applicability in the capsule-filling manufacturing unit.

The major limitations in the existing Contactless Electromagnetic Manufacturing Systems for employing in the capsule-filling manufacturing unit are load bearing limitation, holding force limitation and limitation in the product accessibility. The movers in the existing CEMS are only able to handle limited weights and product densities limiting its overall application in the capsule-filling manufacturing unit. The movers being complicated electromechanical equipment are very sensitive for load bearing capacities. Since in contactless electromagnetic systems, the movers are moved and lifted using electromagnetic forces, the load bearing capacities are severely limited. When a material is filled into containers held by the movers or performing a similar non-contact activity, the CEMS in its present configuration may unable to cater for any significant level of vertical force to be placed on the movers. In an example, the movers in the existing CEMS may be only capable of supporting a maximum weight of between 4.2kg and 6 kg. If the weight of the product as well as any potential product support is taken into consideration, the CEMS may not be able to resist any level of vertical load on the mover.

Any capsule filling activity in the capsule-filling manufacturing unit requires to resist a minimum vertical loading force. If the movers are unable to support the minimum vertical loading force, then the mover will then be pressed downward into the tiles, resulting in major damage to the tiles and the mover, impairing location control and accuracy, misalignment to production machinery, and product damage or failure. Thus, the limitation in load handling in the existing movers restricts overall application of the Contactless Electromagnetic Manufacturing System in capsule-filling manufacturing unit.

Typically, in the capsule-filling manufacturing unit, the capsules are subjected to multiple manufacturing operations that require axial stability and strong holding force. The manufacturing operations in the capsule-filling manufacturing unit requires the magnetic mover to withstand multiple forces and provide strong axial stability by controlling a vertical and horizontal movement of the mover. The mover is subjected to vertical loads from both above and below during different manufacturing operations in the capsule-filling manufacturing unit. For example, in manufacturing operations like capsule loading and capsule filling, a downward force from top to bottom is exerted on the magnetic mover. In other manufacturing operations like capsule recapping and capsule ejection, an upward force from the bottom is exerted on the magnetic mover. The magnetic mover is required to provide a strong holding force by withstanding both the downward force and the upward force. In the existing Contactless Electromagnetic Manufacturing Systems, the mover fails to provide any provision which can actively support any upward force during such manufacturing operations. There is no mechanism available in the existing CEMS that provides stability to the mover subjected to both the upward force and the downward force.

Further, the mover is propelled by the electromagnetic components contained in the mover and the tiles. Each one of the electromagnetic components contains highly sensitive electronics and materials. The electronic components are positioned in a space limited enclosure where there is no access for additional equipment. The movers have no available space inside them for additional equipment to provide the required axial stability and holding force required in the capsule-filling manufacturing unit.

Many of the production processes in the capsule-filling manufacturing unit deliver a large load vertically requiring lateral stability to perform production process accurately. The manufacturing operations in the capsule-filling manufacturing unit operate with extremely high tolerances that require considerable accuracy in lateral movement and provide strong axial stability resisting multiple forces. Typical circumferential clearances between the inside of a capsule and the outside of a body are in the order of 20 micron, this means that if there is any challenge with alignment or product variation there will be production failure. Similar tolerances apply to accurate capsule filling process and the insertion of membranes into the capsules. When placing the capsules under load, the risk of misalignment increases. Additionally any lateral or axial inaccuracies will further increase the loading forces required to complete the manufacturing process, thereby exacerbating the alignment issues. Usually, the movers have stated weight loading capacities which are quoted only in the Z plane, given that these loads are a function of the main repulsive forces between the mover and the manufacturing plane. The forces delivered and the lateral movements in the X and Y planes are a function of variances between the electromagnetic motors within the tiles and are not capable of delivering the same control as in the Z plane. Therefore, the ability for the CEMS to control precise lateral positioning of the movers when placed under load is limited. This limited accuracy is not only in the X, Y and Z coordinates but also with the axial stability of the mover itself during production. The limited accuracy and axial stability of the mover in loaded conditions limits the accuracy, reliability, and quality of products manufactured on the CEMS.

In the existing Contactless Electromagnetic Manufacturing Systems, the tiles are packed full of sensors, stator motors, control electronics and more. In addition, the space between the tiles and movers cannot be used for processing activities. Any added features inside of this space can easily interfere with the tile movement and electromagnetic fields as well as mitigating tile control. Thus, the Contactless Electromagnetic Manufacturing System in its present form is wholly inadequate to cater for the level of forces exerted in the capsule-filling manufacturing unit and are confined only to the movement of product between various points in the manufacturing area. Thus, presently to carry out any key production processes or manufacturing operations, the movers have to be moved outside of the manufacturing plane and in therein defeating the entire purpose of making use of the CEMS.

Further, in the existing Contactless Electromagnetic Manufacturing System, the products are placed on the movers without proving any bottom accessibility. The movers are packed with rare earth magnets which are tightly bonded to one another these magnets are orientated in a particular direction and configuration essential to the operation of the electromagnetic transportation system. The construction of the movers restricts any modifications without affecting the mover's functionality. Thus, any manufacturing activities are to be carried out only by accessing the product from above as there is no bottom access available. The capsule-filling manufacturing process requires bottom access for the capsules to vent, split, recap and provide load and support from the bottom of the capsules during different stages of manufacturing operations such as capsule loading, capsule splitting, capsule recapping and capsule ejection. Therefore, the mover in the present Contactless Electromagnetic Manufacturing System is dedicated to only that of transportation on a surface in which production is carried out. This allows for all manufacturing activities to be carried out only by accessing the product from above. Thus, the electromagnetic system in its current configuration restricts users from having access below the product during manufacturing processes.

Generally, the CEMS allows for location tracking of the movers to identify where the mover is, where it came from, and where it needs to go in the electromagnetic area. Typically, to carry out different manufacturing operations, the movement of the mover might be programmed by the CEMS according to desired manufacturing protocols. Further, the routing of the movers may be then set by the CEMS based on the manufacturing protocols. The movement and tracking of the mover are enabled by assigning a designated address to a production area and a unique identification number for the mover. Similarly, the CEMS may set control points, durations, and actions at particular points as production is being carried out.

The implementation of CEMS in the capsule-filling manufacturing unit requires a high level of complexity involving knowing when the mover has arrived at designated manufacturing station, how long it should be there in the designated manufacturing station, micro indexing, and other functions. Further, there are inter-station complexities that allow variable dosing per product requiring plates to move between multiple stations receiving multiple doses of products, addition of membranes, coatings, and other activities. It is therefore essential that all location, movement, dosing and production activities in the capsule-filling manufacturing unit can be appropriately traced by both the CEMS and the production systems. Further, the level of integration between the CEMS and production systems is highly complex with high levels of risk such as maintaining accuracy in dosing delivered for a particular product. Both the production systems and the CEMS that manage production and the derived recipe for the particular product needs to match and track the capsules and their contents from filling to ejection. It is therefore critical that there be both appropriate integration between production systems and the CEMS as well as a level of security, safety, and redundancy built into the manufacturing process. As the movers are not necessarily permanently attached to production components and given the need for in-production removal, cleaning, replacement, or other reasons, there is a significant risk of tracking movers and not the components holding the capsules.

Thus, in view of the above, it is desirable to provide an electromagnetic mover system that can eliminate one or more of the above-mentioned problems associated with existing art.

SUMMARY
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

In an embodiment of the present disclosure, an electromagnetic mover system for handling capsules in a capsule-filling manufacturing unit is provided. The electromagnetic mover system includes at least one magnetic mover adapted to be moved on an electromagnetic area in the capsule-filling manufacturing unit. The system further includes an elevated support structure attached to the magnetic mover, a gap is defined between a supporting portion of the elevated support structure and a top surface of the magnetic mover. The system includes a body plate adapted to hold a plurality of capsule bodies and having a channel defined underneath each capsule body held in the body plate and at least one body engagement plate adapted to be positioned underneath the body plate and to be engaged with each capsule body via the channel in the body plate.

Further, the body plate is disposed on the supporting portion of the elevated support structure such that an open end of the channel faces the gap defined between the elevated support structure and the top surface of the magnetic mover, and each capsule body is accessible from the channel through the gap. Furthermore, the body engagement plate is adapted to be positioned in the gap such that the body engagement plate accesses each capsule body via the channel.

To further clarify the advantages and features of the present disclosure, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1A illustrates a schematic view of a capsule-filling manufacturing unit, in accordance with an embodiment of the present disclosure;

Figure 1B illustrates a planar view of an electromagnetic mover system, in accordance with an embodiment of the present disclosure;

Figure 1C illustrates an isometric view of the electromagnetic mover system, in accordance with an embodiment of the present disclosure;

Figure 1D illustrates a sectional view of the electromagnetic mover system, in accordance with an embodiment of the present disclosure;

Figure 2A illustrates a sectional view of a cap plate and a body plate with a plurality of capsules, in accordance with an embodiment of the present disclosure;

Figure 2B illustrates a sectional isometric view of the cap plate and the body plate with the plurality of capsules, in accordance with an embodiment of the present disclosure;

Figure 2C illustrates a sectional view of the cap plate and the body plate with a plurality of capsule caps and capsule bodies in accordance with an embodiment of the present disclosure.

Figure 3A illustrates an isometric view of a mover assembly along with the cap plate, in accordance with an embodiment of the present disclosure; and

Figure 3B illustrates a side view of the mover assembly along with the cap plate, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

For example, the term "some" as used herein may be understood as "none" or "one" or "more than one" or "all." Therefore, the terms "none," "one," "more than one," "more than one, but not all" or "all" would fall under the definition of "some." It should be appreciated by a person skilled in the art that the terminology and structure employed herein is for describing, teaching, and illuminating some embodiments and their specific features and elements and therefore, should not be construed to limit, restrict or reduce the spirit and scope of the present disclosure in any way.

For example, any terms used herein such as, "includes," "comprises," "has," "consists," and similar grammatical variants do not specify an exact limitation or restriction, and certainly do not exclude the possible addition of one or more features or elements, unless otherwise stated. Further, such terms must not be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated, for example, by using the limiting language including, but not limited to, "must comprise" or "needs to include."

Whether or not a certain feature or element was limited to being used only once, it may still be referred to as "one or more features" or "one or more elements" or "at least one feature" or "at least one element." Furthermore, the use of the terms "one or more" or "at least one" feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, "there needs to be one or more…" or "one or more elements is required."

Unless otherwise defined, all terms and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by a person ordinarily skilled in the art.

Reference is made herein to some "embodiments." It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.

Use of the phrases and/or terms including, but not limited to, "a first embodiment," "a further embodiment," "an alternate embodiment," "one embodiment," "an embodiment," "multiple embodiments," "some embodiments," "other embodiments," "further embodiment", "furthermore embodiment", "additional embodiment" or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described therein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings. It should be understood that the drawings disclosed herewith are not to scale and nor should quantum and dimension be inferred from them.

Figure 1A illustrates a schematic view of a capsule-filling manufacturing unit 100, in accordance with an embodiment of the present disclosure. Figure 1B illustrates a front view of an electromagnetic mover system 115, in accordance with an embodiment of the present disclosure. Figure 1C illustrates an isometric view of the electromagnetic mover system 115, in accordance with an embodiment of the present disclosure. Figure 1D illustrates a sectional view of the electromagnetic mover system 115, in accordance with an embodiment of the present disclosure.

Capsule-filling manufacturing unit 100 typically involves a series of manufacturing operations carried out one after another in a production sequence. The manufacturing operations in the capsule-filling manufacturing unit 100 may include but not limited to capsule orientation, capsule loading, capsule splitting, capsule filling, capsule recapping and capsule ejection. Each of the manufacturing operation may be carried out by a plurality of stations 101, 103, 105, 107, 109, 111. Each of station in the plurality of stations 101, 103, 105, 107, 109, 111 may be assigned with performing specific manufacturing operation. The manufacturing operations may be carried out sequentially or simultaneously in each of the plurality of stations 101, 103, 105, 107, 109, 111 in the capsule-filling manufacturing unit 100. The plurality of stations 101, 103, 105, 107, 109, 111 may include but not limited to at least one capsule loading station 101, at least one capsule separation station 103, at least one capsule filling station 105, 107, at least one capsule recapping station 109 and at least one capsule ejection station 111, other stations and the number of stations used may be multiplied or combined in a manner appropriate for capsule filling production. In an exemplary embodiment, the capsule loading station 101 may be adapted to load capsules, the capsule separation station 103 may be adapted to separate the capsules into a capsule cap and a capsule body, the capsule filling station 105, 107 may be adapted to fill the capsule body with pharmaceutical, nutraceutical, supplements and other materials, in various formats including powders, granules, beadlets, tablets, pellets and liquids and other formats, suitable for oral dosage delivery, the capsule recapping station 109 may be adapted to combine the capsule cap with the capsule body and the capsule ejection station 111 may be adapted to eject the filled capsules.

An electromagnetic mover system 115 may be employed in the capsule-filling manufacturing unit 100 for carrying out the manufacturing operations. Hereafter, the electromagnetic mover over system 115 may be interchangeably referred to as the system 115. The system 115 may include an electromagnetic area 104 and a non-electromagnetic zone 113. The electromagnetic area 104 may include a plurality of connected tiles on a planar surface. Each tile in the plurality of connected tiles may be provided with electromagnet coils and electronic components that convert a supplied energy into precisely regulated electromagnetic fields.

The electromagnetic mover system 115 may include a plurality of magnetic movers 102 that are adapted to be moved over the electromagnetic area 104. The magnetic mover 102 may be adapted to transport the capsules between the plurality of stations 101, 103, 105, 107, 109, 111 in the system 115. Further, the magnetic movers 102 are dynamic, contactless, and flexible to achieve significant manufacturing efficiency. The production process in the capsule-filling manufacturing unit 100 may be improved by the system 115 through dynamic routing, stacking, and independent travel. Further, the system 100 may facilitate in achieving substantial optimization of manufacturing processes by accommodating rework, blockages, dynamic routing and other optimization strategies.

Further, the magnetic mover 102 may be made up of a plurality of magnets, such as a matrix of rare earth magnets. The plurality of magnets may be stacked and glued together. Magnetic fields may be generated by the plurality of magnets in the magnetic mover 102. The generated magnetic field may push against the electro-magnetic force generated by the plurality of tiles of the electromagnetic area 104 resulting in the movement of the magnetic mover 102 above a surface of the tile. Further, the plurality of tiles may be incorporated with highly sensitive sensors to determine a precise location of the magnetic mover 102. The magnetic mover 102 may be moved omnidirectionally over the electromagnetic area 104 to the precise location. The arrangement of the electromagnetic tiles across the electromagnetic area 104 may be in one of square shaped, rectangular shaped, L-shaped, or annular systems and may also be further configurable. Furthermore, additional tiles may be added to the existing arrangement of the electromagnetic tiles to increase the electromagnetic area 104. The ability to add additional tiles may provide modularity and offers a high level of flexibility for designing scalable and flexible production system115.

Further, the system 115 may include an elevated support structure 106 attached to the magnetic mover 102. Referring to figures 1B and 1C, the elevated support structure 106 may be provided with a supporting portion 118 and an engaging portion 126. The supporting portion 118 may be distal to the engaging portion 126. Furthermore, the engaging portion 126 may be adapted to be positioned on a top surface 130 of the magnetic mover 102. In one embodiment, the elevated support structure 106 may be adapted to be removably coupled to the magnetic mover 102. In another embodiment, the elevated support structure 106 may be integrated with the magnetic mover 102 as a one-piece unitary structure. Moreover, a gap 116 may be defined between the supporting portion 118 of the elevated support structure 106 and the top surface 130 of the magnetic mover 102.

In an embodiment, the engaging portion 126 may be adapted to be removably coupled to a peripheral region of the top surface 130 of the magnetic mover 102. The magnetic mover 102 may include a plurality of second alignment elements positioned on the peripheral region of the magnetic mover 102. The engaging portion 126 may include a plurality of first alignment elements adapted to be coupled to the plurality of second alignment elements. Further, a contour of each first alignment element conforms with a contour of each second alignment element.

Referring to Figures 1B and 1C, the electromagnetic mover system 115 may include at least one body engagement plate 112 adapted to be positioned underneath the body plate 108. The body engagement plate 112 may be engaged with each capsule body 208 (Shown in Figure 2A) via a channel 209 (Shown in Figure 2A) in the body plate 108. The body engagement plate 112 is adapted to be positioned in the gap 116 such that the body engagement plate 112 accesses each capsule body 208 via the channel 209 from below. Furthermore, the body engagement plate 112 may include a plurality of engaging elements 120. Each engaging element in the plurality of engaging elements 120 may be exposed to the channel 209 of the body plate 108 and adapted to apply an upward force on each capsule body 208. When the body engagement plate 112 is moved towards the body plate 108 within the gap 116 from underneath the body plate 108, the plurality of engaging elements 120 may be exposed to a plurality of channels 209 in the body plate 108 via an open end.

In one embodiment, the plurality of engaging elements 120 may be embodied as a plurality of ports. The body engagement plate 112 may be adapted to apply a downward force or a holding force on each capsule body 208 through the channel 209 of the body plate 108. In an embodiment, the downward force applied by the body engagement plate 112 may be a vacuum force. The downward force may be applied via the plurality of engaging elements 120 embodied as the plurality of ports. The plurality of ports may be adapted to be exposed to the open end of the channel 209 in the body plate 108. Each port applies the downward force to each of the channel 209 in the body plate 108. In another embodiment, the plurality of engaging elements 120 may be embodied as a plurality of pins. The body engagement plate 112 may be adapted to apply an upward force or an ejection force on each capsule body 208 through the channel 209 of the body plate 108. The upward force may be applied via the plurality of engaging elements 120 embodied as the plurality of pins. The plurality of pins may be adapted to be attached to the open end of the channel 209 in the body plate 108.

In an embodiment, the body engagement plate 112 may be provided with at least one engaging element. The at least one engaging element may be embodied as an engaging plate. The engaging plate may be adapted to contain ports to deliver a vacuum over the body plate 108 to facilitates a downward force on each capsule body 208.

Referring to Figure 1D, the system 115 may include at least one support structure 114 disposed at a periphery of the electromagnetic area 104 or in a non-electromagnetic zone 113 located outside the electromagnetic area 104. The at least one support structure 114 may be provided in the non-electromagnetic zone 113 to avoid interference with the magnetic components of the system 115 and facilitate free movement of the magnetic mover 102 over the electromagnetic area 104. The at least one support structure 114 may be attached individually with at least one of a cap engagement plate 122, the body engagement plate 112, or a body plate holder 124. The at least one of the cap engagement plate 122, the body engagement plate 112, or the body plate holder 124 may be attached to the at least one support structure 114 individually by a horizontal arm 128. The cap engagement plate 122 may be attached to the support structure 114 above the body plate holder 124 and the body plate holder 124 may be attached to the support structure 114 above the attachment of body engagement plate 112 with the support structure 114. In one embodiment, the cap engagement plate 122 may remain in a fixed position in the support structure 114. In another embodiment, the cap engagement plate 122 may be moved in a vertical direction with respect to the support structure 114 such that the cap engagement plate 122 may engage with the cap plate 110. Similarly, the body engagement plate 112 may be moved in a vertical direction with respect to the support structure 114 such that each channel 209 may be accessed by the body engagement plate 112 from the gap 116 below the body plate 108. In an embodiment, each of the at least one support structure 114, the elevated support structure 106, the body plate 108, the cap engagement plate 122, the body engagement plate 112, or the cap plate 110 may be formed of a non-magnetic material.

Figure 2A illustrates a sectional view of a cap plate 110 and a body plate 108 with a plurality of capsules 202, in accordance with an embodiment of the present disclosure. Figure 2B illustrates a sectional isometric view of the cap plate 110 and the body plate 108 with the plurality of capsules 202, in accordance with an embodiment of the present disclosure. Figure 2C illustrates a sectional view of the cap plate 110 and the body plate 108 with a plurality of capsule caps 206 and capsule bodies 208 in accordance with an embodiment of the present disclosure.

Further, the electromagnetic mover system 115 may include a body plate 108 adapted to be disposed on the supporting portion 118 of the elevated support structure 106. In one embodiment, the cap plate 110 may be adapted to be positioned above the body plate 108. In another embodiment, the body plate 108 may be adapted to receive the cap plate 110 from an external support structure 114. The cap plate 110 and the body plate 108 may be disposed with a plurality of cavities 203, 205. The plurality of cavities 203 in the cap plate 110 aligns with the plurality of cavities 205 in the body plate 108 to form a capsule cavity 201. The capsule cavity 201 may be formed by the alignment of the plurality of cavities 203 in the cap plate 110 and the plurality of cavities 205 the body plate 108 such that a capsule 202 is received therein.

Further, the cap plate 110 may be adapted to hold a capsule cap 206 in each of the cavity 203 defined around each capsule cap 206 held in the cap plate 110. Similarly, the body plate 108 may be adapted to hold a plurality of capsule body 208. The body plate 108 may have the channel 209 defined underneath each capsule body 208 held in the body plate 108. Furthermore, the cap plate 110 may be positioned on the body plate 108 and adapted to be engaged with each capsule cap 206 corresponding to each capsule body 208 resting in the body plate 108. The body plate 108 may be disposed on the supporting portion 118 of the elevated support structure 106 such that the open end of the channel 209 faces the gap 116 defined between the elevated support structure 106 and the top surface 130 of the magnetic mover 102. The disposal of the body plate 108 above the elevated support structure 106 facilitates in accessing each capsule body 208 from the channel 209 through the gap 116.

In a preferred embodiment, the body plate 108 may be removably coupled with the elevated support structure 106. In another embodiment, the body plate 108 may be integrated with the elevated support structure 106 as a one-piece unitary structure.

Figure 3A illustrates an isometric view of a mover assembly 300 along with the cap plate 110, in accordance with an embodiment of the present disclosure. Figure 3B illustrates a side view of the mover assembly 300 along with the cap plate 110, in accordance with an embodiment of the present disclosure.

Further, the system 115 may include one or more alignment mechanisms to align the body plate 108 with the supporting portion 118 of the elevated support structure 106. The elevated support structure 106 may include a plurality of second alignment elements positioned on a peripheral region of the elevated support structure 106 and the body plate 108 may include a plurality of first alignment elements. The first alignment elements in the body plate 108 may be adapted to be coupled with the second alignment elements in the elevated support structure 106. Further, a contour of each first alignment element conforms with a contour of each second alignment element. In an embodiment, the first alignment element may be embodied as a raised formation, a recess or a combination of both and the second alignment element may be embodied as the raised formation, the recess or a combination of both.

In one embodiment, the alignment mechanism may include at least two or more raised formation formed on the supporting portion 118 of the elevated support structure 106. Each raised formation may be adapted to be received within a respective recess provided on the body plate 108 such that the body plate 108 may be aligned with the elevated support structure 106. In another embodiment, the alignment mechanism may include at least two or more raised formations formed on the body plate 108. Each raised formation is adapted to be received within a respective recess provided on the supporting portion 118 of the elevated support structure 106 such that the body plate 108 is aligned with the elevated support structure 106. In yet another embodiment, the alignment mechanism may include at least one raised formation and at least one recess formed on the body plate 108 and corresponding at least one raised formation and at least one recess formed on the supporting portion 118 of the elevated support structure 106. Each raised formation in the body plate 108 is adapted to be received within a respective recess provided on the body plate 108 and each raised formation in the supporting portion 118 of the elevated support structure 106 is adapted to be received within a respective recess provided on the body plate 108 such that the body plate 108 is aligned with the elevated support structure 106. In yet another embodiment, a contour of a periphery of the body plate 108 conforms with a contour of a periphery of the supporting portion 118 of the elevated support structure 106, such that the body plate 108 is aligned with the elevated support structure 106.

Further, the system 115 may include one or more alignment mechanisms to align the body plate 108 with the cap plate 110. The body plate 108 may include a plurality of second alignment elements positioned on a peripheral region of the body plate 108 and the cap plate 110 may include a plurality of first alignment elements. The first alignment elements in the cap plate 110 may be adapted to be coupled with the second alignment elements in the body plate 108. Further, a contour of each first alignment element conforms with a contour of each second alignment element. In an embodiment, the first alignment element may be embodied as the raised formation, the recess or a combination of both and the second alignment element may be embodied as the raised formation, the recess or a combination of both.

In one embodiment, the alignment mechanism may include at least two or more raised formations formed on the body plate 108. Each raised formation is adapted to be received within a respective recess provided on the cap plate 110 such that the body plate 108 is aligned with the cap plate 110. In another embodiment, the alignment mechanism may include at least two or more raised formations formed on the cap plate 110. Each raised formation is adapted to be received within a respective recess provided on the body plate 108 such that the cap plate 110 is aligned with the body plate 108. In yet another embodiment, the alignment mechanism may include at least one raised formation and at least one recess formed on the body plate 108 and corresponding at least one raised formation and at least one recess may be provided on the cap plate 110. Each raised formation in the body plate 108 is adapted to be received within a respective recess provided on the cap plate 110 and each raised formation in the cap plate 110 is adapted to be received within a respective recess provided on the body plate 108 such that the body plate 108 is aligned with the cap plate 110. In yet another embodiment, a contour of a periphery of the cap plate 110 conforms with a contour of the periphery of the body plate 108, such that the cap plate 110 is aligned with the body plate 108.

In an embodiment, the raised formation of the alignment mechanism may have different shapes, such as a cylindrical shape, a cuboidal shape, a conical shape, or any other shape known in the art, without departing from the scope of the present disclosure. Further, a shape of the recess may conform with the shape of the corresponding raised formation. The recess may have different shapes, such as a cylindrical shape, a cuboidal shape, a conical shape, or any other shape known in the art, without departing from the scope of the present disclosure. The embodiments disclosed herein should not be construed as limiting and different alignment mechanisms may be employed to align the cap plate 110, the body plate 108, and the elevated support structure 106. Further, the aligning mechanism facilitates in accurately positioning the elevated support structure 106, the body plate 108, and the cap plate 110 over the magnetic mover 102.

In a non-limiting embodiment, the body plate 108, the elevated support structure 106, and the magnetic mover 102 are integrated as a one-piece unitary structure and may constitute the mover assembly 300. Many of the production operations in the capsule-filling manufacturing unit 100 deliver multiple forces that require lateral, vertical and axial stability to perform production process accurately. The mover assembly 300 may be required to withstand the multiple forces and provide the lateral, vertical and axial stability to perform different manufacturing operations. The mover assembly 300 by itself may not be capable to provide the required stability during the manufacturing operations. The at least one support structure 114 may be adapted to provide the required stability to the mover assembly 300 during the manufacturing operations in the capsule-filling manufacturing unit 100. The at least one support structure 114 may attach with the mover assembly 300 in each of the stations during performing each of the manufacturing operations and provide the required lateral, vertical, and axial stability to the mover assembly 300. Further, the mover assembly 300 may be subjected to multiple forces including the upward force and the downward force during the manufacturing operations.

The mover assembly 300 without any support structure 114 may not be able to withhold any of the forces that are required to perform the manufacturing operations in the capsule-filling manufacturing unit 100. In other words, to perform manufacturing operations in the capsule-filling manufacturing unit 100 by the system 115, it is imperative to have the at least one support structure 114 to provide the lateral, vertical, and axial stability to the mover assembly 300.

In one embodiment, the magnetic mover 102 may be configured to move over the electromagnetic area 104 to the plurality of stations 101, 103, 105, 107, 109, 111 in the capsule-filling manufacturing unit 100. In another embodiment, the magnetic mover 102 may be configured to be indexed for moving the elevated support structure 106 to a plurality of predefined positions within each station. The system 115 may be configured for particular recipe-based formulations for one of individual or batches of products. Further, the system 115 may be configured to transport at least one of the capsule 202, the capsule cap 206 or the capsule body 208 within the capsule-filling manufacturing unit 100 and directed to at least one of the plurality of stations 101, 103, 105, 107, 109, 111.

Further, each station in the plurality of stations 101, 103, 105, 107, 109, 111 may be provided with the at least one of the support structure 114. Each station may be adapted to perform a specific operation. The capsule loading station 101 may be adapted to load capsules 202 into the capsule cavity 201. The capsule separation station 103 may be adapted to separate the capsule cap 206 from the capsule body 208. The capsule filling station 105, 107 may be adapted to fill the capsule body 208 with a variety of materials in powder, beadlet, granular, liquid, or other form. In an embodiment, the capsule filling operation may also be carried out over a number of different filling stations to facilitate multiple ingredient dosing. The capsule recapping station 109 may be adapted to reattach the capsule cap 206 with the capsule body 208 and the capsule ejection station 111 may be adapted to eject the recapped capsules 202 from the cap plate 110 and the body plate 108.The capsule-filling manufacturing unit may contain additional stations that may perform a variety of additional functions to best make use of the system 115. The additional functions may include but not limited to insertion of membranes, weighing of capsules, application of coatings or other functional activities relevant to capsule filling and manufacturing. The working mechanism of the operations performed by each of the station is described in detail in subsequent paragraphs.

In an embodiment, the magnetic mover 102 may be adapted to be moved over the electromagnetic area 104 to a capsule loading station 101 from among the plurality of stations 101, 103, 105, 107, 109, 111. In one embodiment, the magnetic mover 102 may be adapted to be moved along with the elevated support structure 106, the cap plate 110, and the body plate 108. In another embodiment, the magnetic mover 102 may be adapted to be moved along with the elevated support structure 106 and the body plate 108. The body plate 108 may be adapted to receive the cap plate 110 from the at least one support structure 114. The magnetic mover 102 is positioned in the capsule loading station 101 such that the at least one support structure 114 is attached to the body plate 108 via the body plate holder 124. The magnetic mover 102 may be moved and positioned at the capsule loading station 101 such that the body plate 108 may be vertically positioned above the body engagement plate 112 in the gap 116 of the elevated support structure 106.

Further, the body plate holder 124 may be attached to the body plate 108 through a coupling mechanism. In the illustrated embodiment, the coupling mechanism may include a slot 204 disposed along an outer circumference of the body plate 108. The slot 204 may be adapted to be engaged with an extension in the body plate holder 124. In another embodiment, the coupling mechanism may include a slot 204 disposed along an inner circumference of the body plate holder 124. The slot 204 may be adapted to be engaged with an extension in the body plate 108. In an exemplary embodiment of the elevated support structure 106 and the body plate 108 being the one-piece unitary structure, the body plate holder 124 may be adapted to be attached with the one-piece unitary structure. The embodiments disclosed herein should not be construed as limiting and different coupling mechanisms known in the art may be employed to removably attach the body plate holder 124 with the body plate 108.

Further, the body plate holder 124 may be attached to the body plate 108 such that the support structure 114 supports load on the body plate 108 during the capsule loading process. During the capsule loading process, the mover 102 may be subjected to vertical loads by way of capsules being inserted into the cap plate 110 and the body plate 108. The attachment of the body plate holder 124 with the body plate 108 may increase the ability of the mover 102 to resist vertical and horizontal movement during capsule loading process. Further, the body plate holder 124 may provide stability to the body plate 108 and increases load bearing capacity in the magnetic mover 102.

Further, at the capsule loading station 101, the plurality of capsules 202 may be dispensed from a hopper into the capsule cavity 201 formed between the cap plate 110 and the body plate 108. The plurality of capsules 202 may be dispensed in the cap plate 110 positioned over the body plate 108 such that the capsule cap 206 is located within the cap plate 110 and the capsule body 208 is located within the body plate 108. Each of the plurality of cavities 203 in the cap plate 110 is provided with a ridgeline formation at the base of the cavity 203. The ridgeline in the plurality of cavities 203 of the cap plate 110 may be narrower than an external diameter of the capsule cap 206 and larger than the capsule body 208. During the capsule loading process, when the capsules 202 are dispensed into the capsule cavity, the ridgeline provides a surface for the capsule cap 206 to rest and limits the capsules 202 from falling through the cap plate 110 and the body plate 108.

Further, when the capsules 202 are dispensed into the capsule cavity 201, the volume of each capsule 202 displaces an empty volume inside each of the capsule cavity 201creating a buildup of back pressure. The back pressure built up during the capsule loading process may be vented out into the gap 116 via the open end of the channel 209 in the body plate 108. In particular, during loading of the capsules 202, the gap 116 defined below the body plate 108 in the elevated support structure 106 allows for releasing the back pressure to an ambient environment.

Further, the plurality of engaging elements 120 in the body engagement plate 112 may be adapted to apply a downward force in each channel 209 to pull the capsule 202 into the capsule cavity 201. In a preferred embodiment, the plurality of engaging elements 120 in the body engagement plate 112 is embodied as the plurality of ports. In an embodiment, the downward force may be a vacuum applied by the plurality of engaging elements 120 onto the open end of the channels 209 in the body plate 108. The downward force facilitates in guiding or positioning the capsules 202 into the capsule cavity 201. The capsule 202 may be pulled into the plurality of cavities 203, 205in the cap plate 110 and the body plate 108, respectively, by the downward force.

After the capsule loading station 101, the magnetic mover 102 may be adapted to be moved over the electromagnetic area 104 to the capsule separation station 103 from among the plurality of stations 101, 103, 105, 107, 109, 111. In a preferred embodiment, the magnetic mover 102 may be adapted to be moved along with the elevated support structure 106, the cap plate 110, and the body plate 108. The magnetic mover 102 is positioned in the capsule separation station 103 such that at least one support structure 114 is attached to the body plate 108 via the body plate holder 124. Further, the magnetic mover may be moved and positioned at the capsule separation station 103 such that the body plate 108 may be vertically positioned above the body engagement plate 112 in the gap 116 of the elevated support structure 106.

The body plate holder 124 may be attached to the body plate 108 through the coupling mechanism. In the illustrated embodiment, the coupling mechanism may include the slot 204 disposed along the outer circumference of the body plate 108. The slot 204 may be adapted to be engaged with the extension in the body plate holder 124. In another embodiment, the coupling mechanism may include the slot 204 disposed along the inner circumference of the body plate holder 124. The slot 204 may be adapted to be engaged with the extension in the body plate 108.
In an exemplary embodiment of the elevated support structure 106 and the body plate 108 being the one-piece unitary structure, the body plate holder 124 may be adapted to be attached with the elevated support structure 106. The embodiments disclosed herein should not be construed as limiting and different coupling mechanisms known in the art may be employed to removable attach the body plate holder 124 with the body plate 108.

Further, the body plate holder 124 is attached with the body plate 108 such that the support structure 114 supports load on the body plate 108 during the capsule separation process. During the capsule separation process, the magnetic mover 102 may be subjected to vertical loads by way of vertical movement of the cap plate 110 with respect to the body plate 108. The attachment of the body plate holder 124 with the body plate 108 may increase the ability of the mover 102 to resist vertical movement during capsule separation process. Further, the body plate holder 124 may provide stability to the body plate 108 and may resist in horizontal movement during separation of the capsule cap 206 from the capsule body 208.

Further, the capsule cap 206 and the capsule body 208 may be separated in the capsule separation station 103 in two stages. Firstly, by application of the downward force by the body engagement plate 112 in holding down the capsule bodies 208 within the body plate 108. Secondly, by removal of the cap plate 110 by lifting vertically the cap plate 110 via the cap engagement plate 122. The body engagement plate 112 may apply the downward holding force on each capsule body 208 through the channel 209 such that each capsule cap 206 is separated from each capsule body 208. In an embodiment, the downward holding force is a vacuum applied by the plurality of engaging elements 120 onto the open end of the channel 209 in the body plate 108. In a preferred embodiment, the plurality of engaging elements 120 in the body engagement plate 112 is embodied as the plurality of ports. After the magnetic mover 102 engages with the support structure 114 in the capsule separation station 103, the cap engagement plate 122 may be moved in a downward direction to engage with the cap plate 110. The cap plate 110 may be adapted to be lifted by the cap engagement plate 122 in an upward direction with respect to the body plate 108. The combination of applying download holding force by the plurality of engaging elements 120 and the lifting of the cap plate 110 by the cap engagement plate 122 facilitates in separating the capsule cap 206 from the capsule body 208.

After the capsule separation station 103, the magnetic mover 102 may be adapted to be moved over the electromagnetic area 104 to at least one capsule filling station 105, 107 from among the plurality of stations 101, 103, 105, 107, 109, 111.
In the present description for sake of clarity it has been assumed that two filling stations 105, 107 are provided in the capsule-filling manufacturing unit 100. The example of two capsule filling station 105, 107 is merely illustrative and it is to be understood by those skilled in the art that various modifications in form and detail may be made therein without departing from or offending the spirit and scope of the present invention.

In a preferred embodiment, the magnetic mover 102 may be adapted to be moved along with the elevated support structure 106 and the body plate 108. The magnetic mover 102 is positioned in the capsule filling station 105, 107 such that the at least one support structure 114 is attached to the body plate 108 via the body plate holder 124. Further, the magnetic mover 102 may be moved and positioned at the capsule filling station 10 such that the body plate 108 may be vertically positioned above the body engagement plate 112 in the gap 116 of the elevated support structure 106.

Further, the body plate holder 124 may be attached to the body plate 108 through the coupling mechanism. In the illustrated embodiment, the coupling mechanism may include the slot 204 disposed along the outer circumference of the body plate 108. The slot 204 may be adapted to be engaged with the extension in the body plate holder 124. In another embodiment, the coupling mechanism may include the slot 204 disposed along the inner circumference of the body plate holder 124. The slot 204 may be adapted to be engaged with the extension in the body plate 108. In an exemplary embodiment of the elevated support structure 106 and the body plate 108 being the one-piece unitary structure, the body plate holder 124 may be adapted to be attached with the elevated support structure 106. The embodiments disclosed herein should not be construed as limiting and different coupling mechanisms known in the art may be employed to removable attach the body plate holder 124 with the body plate 108.

Further, the body plate holder 124 may be attached with the body plate 108 such that the support structure 114 supports load on the body plate 108 during the capsule filling process. During the capsule filling process, the magnetic mover 102 may be subjected to vertical loads by way of filling pharmaceutical, nutraceuticals, supplements, nutrition or other materials into the capsule body 208. The attachment of the body plate holder 124 with the body plate 108 may increase the ability of the mover 102 to resist vertical and horizontal movement during the capsule filling process. Further, the body plate holder 124 may provide stability to the body plate 108 and increases load bearing capacity in the mover 102.

The at least one capsule filling station 105, 107 may be adapted to fill the capsules body 208 with a variety of materials in powder, beadlet, granular, liquid or any other form. In a non-limiting embodiment, additional activities may take place in the capsule filling station such as, insertion of membranes to separate the body compartments, applying coatings and any other activities relevant to capsule filling process. The materials may be dispensed within the plurality of capsule body 208 held in the plurality of cavities 205 of the body plate 108. Further, the magnetic mover 102 may be indexed for micro movements within the capsule filling station 105, 107. The magnetic mover 102 may be configured to make micro movements such that the body plate 108 is moved to receive the pharmaceutical material in each of the capsule body 208.

Further, the body plate 108 may be configured to be identified by the capsule filling station 105, 107, from among the plurality of stations 101, 103, 105, 107, 109, 111 to determine a level of dosing to be applied. The system 115 may identify the body plate 108 to ensure the correct body plate 108 for the production batch may be arrived at the capsule filling station 105, 107. The capsule filling station 105 107 may be provided with a scanner to scan a unique identifier from the body plate 108. In an embodiment, the identifier may be one of, but not limited to, a barcode, a Radio Frequency (RF) tag, and any other means of identification. Upon identifying the body plate 108, the system 115 may determine the quantity of material that needs to be filled in the capsule bodies 208 carried by the identified body plate 108. The identification of the body plate 108 enables the system 115 to individually map the capsule bodies 208 with the materials or ingredients dispensed during the capsule filling process. Further, by identifying the body plate 108, the system 115 may also track dosing of any of the capsule bodies 208 by mapping the capsule bodies 208 with the respective capsule filling stations 105,107. Furthermore, the identification of the body plate 108 may facilitate the system 115 to process multiple products simultaneously in the capsule-filling manufacturing unit 100 and allows for variable dosing in the capsule filling stations 105, 107.
Further, the support structure 114 may be adapted to resist vertical and horizontal loads placed on the body plate 108 and resist a horizontal and vertical movement of the body plate 108 during the capsule filling process. The engagement of the body plate holder 124 with the body plate 108 facilitates in providing additional support during the capsule filling process. Furthermore, the support structure 114 is adapted to provide stability to the mover assembly 300 during the capsule filling process.

After the capsule filling station 105, 107, the magnetic mover 102 may be adapted to be moved over the electromagnetic area 104 to the capsule recapping station 109 from among the plurality of stations 101, 103, 105, 107, 109, 111. In a preferred embodiment, the magnetic mover 102 may be adapted to be moved along with the elevated support structure 106 and the body plate 108. The magnetic mover 102 is positioned in the capsule recapping station 109 such that at least one support structure 114 is attached to the body plate 108 via the body plate holder 124. Further, the magnetic mover 102 may be moved and positioned at the capsule recapping station 109 such that the body plate 108 may be vertically positioned above the body engagement plate 112 in the gap 116 of the elevated support structure 106.

Further, the body plate holder 124 may be attached to the body plate 108 through the coupling mechanism. In the illustrated embodiment, the coupling mechanism may include the slot 204 disposed along the outer circumference of the body plate 108. The slot 204 may be adapted to be engaged with the extension in the body plate holder 124. In another embodiment, the coupling mechanism may include the slot 204 disposed along the inner circumference of the body plate holder 124. The slot 204 may be adapted to be engaged with the extension in the body plate 108. In an exemplary embodiment of the elevated support structure 106 and the body plate 108 being the one-piece unitary structure, the body plate holder 124 may be adapted to be attached with the elevated support structure 106. The embodiments disclosed herein should not be construed as limiting and different coupling mechanisms known in the art may be employed to removable attach the body plate holder 124 with the body plate 108.

Further, the body plate holder 124 may be attached with the body plate 108 such that the support structure 114 resists load on the body plate 108 during the capsule recapping process. During the capsule recapping process, the magnetic mover 102 may be subjected to vertical loads by way of vertical movement of the cap plate 110 with respect to the body plate 108. The attachment of the body plate holder 124 with the body plate 108 may increase the ability of the mover 102 to resist vertical movement during capsule recapping process. Further, the body plate holder 124 may provide stability to the body plate 108 and may resist in horizontal movement during recapping of the capsule body 208 with the capsule cap 206.

As earlier mentioned, the cap plate 110 holding the capsule cap 206 has the ridgeline supporting the open ends of the capsule cap 206. The ridgeline in the cap plate 110 formation limits the capsule cap 206 from falling through the cap plate 110. Due to the presence of the ridgeline in the cap plate 110, the capsule cap 206, and the capsule body 208 may not be rejoined by pushing the capsule cap 206 down onto the bodies. Rather, the capsule bodies 208 may be pushed upwards into the capsule cap 206 by the plurality of engaging elements 120 in the body engagement plate 112. The gap 116 below the body plate 108 in the elevated support structure 106 enables movement of the plurality of engaging elements in the 120 in the body engagement plate 112. Further, in order for the capsule cap 206 and the capsule body 208 to remain firmly engaged with one another and avoid separation and spillage, both the capsule cap 206 and the capsule body 208 have circumferentially profiled ridge formations designed to mate the capsule cap 206 and capsule body 208 to one another. The process of recapping the capsule cap 206 with the capsule body 208 involves deforming sidewalls of the capsule cap 206 and the capsule body 208 until they engage with one another in a mated arrangement.

Further, at the capsule recapping station 109, the at least one support structure 114 may be attached to the cap engagement plate 122 and the cap engagement plate 122 may be adapted to be moved in a downward direction to engage with the cap plate 110. The cap engagement plate 122 engages with the cap plate 110 to resist the upward force applied by the body engagement plate 112 on the capsule body 208. Once the cap plate 110 may be secured by the cap engagement plate 122, the body engagement plate 112 may apply an upward force on each capsule body 208 in the body plate 108. The upward force may be applied via the plurality of engaging elements 120 such that the capsule cap 206 and the capsule body 208 are recapped to form the capsule 202. In a preferred embodiment, the plurality of engaging elements 120 in the body engagement plate 112 is embodied as the plurality of pins. The cap engagement plate 122 may resist a vertical movement of the body plate 108 during the recapping process. Furthermore, the body plate 108 may be attached to the support structure 114 via the body plate holder 124 such that the support structure 114 distributes horizontal and vertical loads placed on the body plate 108 during the capsule recapping process.

Further, during the capsule recapping process, the cap engagement plate 122 may be adapted to resist a predefined amount of the upward force applied by the body engagement plate 112 to enable attachment of the capsule cap 206 with the capsule body 208. In an embodiment, the predefined amount of the upward force applied by the body engagement plate 112 is at least 25 newtons.

After the capsule recapping station 109, the magnetic mover 102 may be adapted to be moved over the electromagnetic area 104 to the capsule ejection station 111 from among the plurality of stations 101, 103, 105, 107, 109, 111. In an embodiment, the magnetic mover 102 may be adapted to be moved along with the elevated support structure 106, the cap plate 110, and the body plate 108. The magnetic mover 102 is positioned in the capsule ejection station 111 such that at least one support structure 114 is attached to the body plate 108 via the body plate holder 124. Further, the magnetic mover 102 may be moved and positioned at the capsule ejection station 111 such that the body plate 108 may be vertically positioned above the body engagement plate 112 in the gap 116 of the elevated support structure 106.

Further, the body plate holder 124 may be attached to the body plate 108 through the coupling mechanism. In the illustrated embodiment, the coupling mechanism may include the slot 204 disposed along the outer circumference of the body plate 108. The slot 204 may be adapted to be engaged with the extension in the body plate holder 124. In another embodiment, the coupling mechanism may include the slot 204 disposed along the inner circumference of the body plate holder 124. The slot 204 may be adapted to be engaged with the extension in the body plate 108. In an exemplary embodiment of the elevated support structure 106 and the body plate 108 being the one-piece unitary structure, the body plate holder 124 may be adapted to be attached with the elevated support structure 106. The embodiments disclosed herein should not be construed as limiting and different coupling mechanisms known in the art may be employed to removable attach the body plate holder 124 with the body plate 108.

At the capsule ejection station 111, the capsules 202 may be ejected from the cap plate 110 and the body plate 108. Given the disclosed ridgeline formation in the cap plate 110, the capsules 202 may not be pushed down from the cap plate 110 and the body plate 108. Rather, to eject the capsules 202, the capsules 202 may need to be pushed from below via the open end of the channels 209 in the body plate 108. The body engagement plate 112 may be adapted to apply the upward force via the plurality of engaging elements 120 on each capsule body 208 such that the capsule 202 is ejected from the cap plate 110 and the body plate 108. In a preferred embodiment, the plurality of engaging elements 120 in the body engagement plate 112 is embodied as the plurality of pins. Furthermore, the at least one support structure 114 may be adapted to distribute loads exerted on the body plate 108 and the cap plate 110 when the body engagement plate 112 applies the upward force for ejecting the capsule 202. The at least one support structure 114 resist a horizontal and vertical movement of the body plate 108 during the capsule ejection process. The ejected capsules may be collected in a collection bin and proceeded for packaging.

The advantages of the electromagnetic mover system 115 are explained below. The electromagnetic mover system 115 implements electromagnetic technologies to replace the existing sequential manufacturing process in the capsule-filling manufacturing unit 100. The electromagnetic mover system 115 allows for highly accurate and free movement of the mover assembly 300 holding the capsules 202. The system 115 as disclosed in the present disclosure enables for effective implementation in the capsule-filling manufacturing unit 100. The system 115 in its present configuration is able to cater for significant level of vertical loads and forces applied on the mover assembly 300. The at least one support structure 114 is capable of resisting and supporting the vertical loading force on the mover assembly 300 during any of the manufacturing operations in the capsule-filling manufacturing unit 100.

Further, the mover assembly 300 may be subjected to the vertical loads from both above and below during different manufacturing operations in the capsule-filling manufacturing unit 100. For example, in manufacturing operations like capsule loading and capsule filling, the downward force from top to bottom is exerted on the mover assembly 300. In other manufacturing operations like capsule recapping and capsule ejection, the upward force from the bottom is exerted on the mover assembly 300. The system 115 as disclosed in the present invention is capable of withstanding multiple forces on the mover assembly 300. The at least one support structure 114 provide strong axial stability by controlling the vertical and horizontal movement of the mover assembly 300 during any of the manufacturing operations. The at least one support structure 114 provides a strong holding force for the mover assembly 300 by withstanding both the downward force and the upward force during any of the manufacturing operations.

Many of the production processes in the capsule-filling manufacturing unit 100 deliver a large load vertically requiring lateral stability of the mover assembly 300 to perform production process accurately. The system 115 provides for precise lateral positioning of the mover assembly 300 under load conditions. The at least one of the support structures 114 in the system 115 provides considerable accuracy in lateral movement and provide strong axial stability resisting multiple forces. Further the system provides for accurate movement of the mover assembly 300 along the X, Y and Z coordinates above the manufacturing plane. The improved accuracy and axial stability of the mover assembly 300 in loaded conditions assures reliability, and quality of products manufactured by the system 115.

Accessing bottom of the capsule 202 is crucial to carry out key manufacturing operations in the capsule-filling manufacturing unit 100. The gap 116 defined in the elevated support structure 106 allows for accessing the bottom of the capsules 202 by the body engagement plate 112. Owing to such constructional details, the mover assembly 300 as disclosed in the present disclosure allows for the system 115 to perform each of the manufacturing operations in the capsule-filling manufacturing unit 100. Firstly, during capsule loading operation, the gap 116 in the elevated support structure 106 allows to vent the back pressure and may facilitate the application of a vacuum to guide the capsules 202 into the capsule cavity. Secondly, during capsule splitting operation, the gap 116 in the elevated support structure 106 allows the body engagement plate 112 to apply vacuum via the open end of the channels in the body plate. Thirdly, during capsule recapping operation, the gap 116 in the elevated support structure allows the body engagement plate 112 to push the plurality of capsule body 208 against the plurality of capsule cap 206. Fourthly, during capsule ejection operation, the body engagement plate 112 is positioned below the body plate 108 and pushed through the gap 116 via the open end of the channels 209 to eject the capsules 202.

Further, the at least one support 114 structure in each of the stations 101, 103, 105, 107, 109, 111 provide structural support to the magnetic mover 102. Many of the production operations in the capsule-filling manufacturing unit 100 deliver multiple forces that require lateral, vertical, and axial stability to perform the production process accurately. The mover assembly 300 may be required to withstand the multiple forces and provide the lateral, vertical, and axial stability to perform different manufacturing operations. The mover assembly 300 by itself may not be capable of providing the required stability during the manufacturing operations. The support structure 114 may be adapted to provide the required stability to the mover assembly 300 during the manufacturing operations in the capsule-filling manufacturing unit 100. The support structure 114 may attach with the mover assembly 300 in each of the stations during performing each of the manufacturing operations and provide the required lateral, vertical, and axial stability to the mover assembly 300. The at least one support structure 114 resist the lateral and vertical movement of the magnetic mover 102 during any of the manufacturing operations.

Further, the system 115 is capable of dynamically moving the capsules through the production process that allows for modular scaling of production by adding or removing production stations as desired. The modularity allows to increase stations with slow indexing times, thereby optimizing production cycle times and significant improvement in production output. The system 115 provides for the ability to infeed and outfeed between production lines and sub production areas may be carried out with smart and efficient scheduling. Furthermore, the system 115 provides for the ability to dynamically route product in the manufacturing process according to real time availability of production stations thereby maximizing production output and utilization. The system 115 further provides for the ability to stack products in production process dynamically within the production area, thereby ensuring quantities of buffer items which ensure there is no production waiting times and maximizing efficiency. The system 115 further provides for the ability to stack products in progress in the event of stoppages, cleaning or maintenance without stopping upstream processes. Furthermore, the system provides for the ability to change out batches quickly by only replacing selected modular stations.

While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. , Claims:1. An electromagnetic mover system (115) for handling capsules in a capsule-filling manufacturing unit (100), the electromagnetic mover system (115) comprising:
at least one magnetic mover (102) adapted to be moved on an electromagnetic area (104) in the capsule-filling manufacturing unit 100;
an elevated support structure (106) attached to the magnetic mover (102), wherein a gap (116) is defined between a supporting portion (118) of the elevated support structure (106) and a top surface (130) of the magnetic mover (102);
a body plate (108) adapted to hold a plurality of capsule bodies and having a channel (209) defined underneath each capsule body (208) held in the body plate (108); and
at least one body engagement plate (112) adapted to be positioned underneath the body plate (108) and to be accessed with each capsule body (208) via the channel (209) in the body plate (108),
wherein the body plate (108) is disposed on the supporting portion (118) of the elevated support structure (106) such that an open end of the channel (209) faces the gap (116) defined between the elevated support structure (106) and the top surface (130) of the magnetic mover (102), and each capsule body (208) is accessible from the channel (209) through the gap (116), and
wherein the body engagement plate (112) is adapted to be positioned in the gap (116) such that the body engagement plate (112) accesses each capsule body (208) via the channel (209).

2. The system (115) according to claim 1, wherein:
the body engagement plate (112) comprises a plurality of engaging elements (120), each engaging element is to be aligned with the channel (209) of the body plate (108) and adapted to apply an upward force on each capsule body (208) when the body engagement plate is moved towards the body plate (108) within the gap (116) from underneath the body plate (108).

3. The system (115) according to claim 2, wherein the plurality of engaging elements (120) is embodied as a plurality of pins.

4. The system (115) according to claim 2, wherein:
the body engagement plate (112) is adapted to apply a downward force on each capsule body (208) through the channel (209) of the body plate (108).

5. The system (115) according to any of the preceding claims, further comprising:
at least one support structure (114) disposed at a periphery of the electromagnetic area (104) or in a non-electromagnetic zone located outside the electromagnetic area (104),
wherein the at least one support structure (114) is attached individually with at least one of a cap engagement plate (122), the body engagement plate (112), or a body plate holder (124),

6. The system (115) according to claim 1, wherein the body plate (108) is removably coupled with the supporting portion (118) of the elevated support structure (106).

7. The system (115) according to claim 6, comprises two or more alignment mechanisms to align the body plate (108) with the supporting portion (118) of the elevated support structure (106).

8. The system (115) according to claim 7, wherein the alignment mechanism comprises:

wherein the elevated support structure (106) comprises a plurality of second alignment elements positioned on the peripheral region of the elevated support structure (106) and the body plate (108) comprises a plurality of first alignment elements adapted to be coupled to the second alignment elements,
wherein a contour of each first alignment element conforms with a contour of each second alignment element.

9. The system (115) according to claim 1, wherein the elevated support structure (106) is removably coupled to the magnetic mover (102).

10. The system (115) according to claim 9, wherein:
the elevated support structure (106) comprises an engaging portion (126) distal to the supporting portion (118), the engaging portion (126) is adapted to be positioned on the top surface (130) of the magnetic mover (102) and removably coupled to a peripheral region of the top surface (130) of the magnetic mover (102),
wherein the magnetic mover (102) comprises a plurality of second alignment elements positioned on the peripheral region of the magnetic mover and the engaging portion comprises a plurality of first alignment elements adapted to be coupled to the second alignment elements,
wherein a contour of each first alignment element conforms with a contour of each second alignment element.

11. The system (115) according to claim 1, wherein the elevated support structure (106) is integrated with the magnetic mover (102) as a one-piece unitary structure.

12. The system (115) according to claim 1, wherein the body plate (108) is integrated with the elevated support structure (106) as a one-piece unitary structure.

13. The system (115) according to claim 1, wherein the body plate (108), the elevated support structure (106), and the magnetic mover (102) are integrated as a one-piece unitary structure.

14. The system (115) according to any of the preceding claims, wherein the body engagement plate (112) comprises a plurality of ports adapted to be in connection with the body plate (108) via the open ends of the channels (209) in the body plate (108).

15. The system (115) according to claim 14, wherein:
a vacuum is applied via the plurality of ports in the body engagement plate (112) to each channel (209) of the body plate (108).

16. The system (115) according to any of the preceding claims, further comprising:
a cap plate (110) to be positioned on the body plate (108) and adapted to be engaged with each capsule cap (206) corresponding to each capsule body (208) resting in the body plate (108).

17. The system (115) according to any of the preceding claims, wherein:
the magnetic mover (102) is adapted to be moved over the electromagnetic area (104) to a capsule loading station 101 from among a plurality of stations (101, 103, 105, 107, 109, 111),
wherein, at the capsule loading station 101, the plurality of capsules are dispensed in the cap plate (110) positioned over the body plate (108) such that the capsule cap (206) is located within the cap plate (110) and the capsule body (208) is located in the body plate (108),
wherein a back pressure inside each channel (209) of the body plate (108) is released into the gap (116) via the open end of the channel (209) in the body plate (108) when each channel (209) receives the capsule body (208).

18. The system (115) according to claim 17, wherein the plurality of engaging elements (120) in the body engagement plate (112) is adapted to apply a downward force in each channel (209) to pull the capsule body (208) down and away from the capsule cap (206) in the cap plate (110) and the body plate (108) respectively.

19. The system (115) according to any of claims 17-18, wherein, at the capsule filling station, the at least one support structure (114) is attached to the body plate (108) via the body plate holder (124) such that the support structure (114) supports loads on the body plate (108) during a capsule filling process.

20. The system (115) according to any of the preceding claims, wherein:
the magnetic mover (102) is adapted to be moved over the electromagnetic area (104) to a capsule separation station 103 from among the plurality of stations (101, 103, 105, 107, 109, 111),
wherein, at the capsule separation station 103, the cap plate (110) is adapted to be lifted by the cap engagement plate (122) in an upward direction with respect to the body plate (108)during a capsule separation process. .

21. The system (115) according to any of the preceding claims, wherein:
the magnetic mover (102) is adapted to be moved over the electromagnetic area (104) to at least one capsule filling station 105, 107 from among the plurality of stations (101, 103, 105, 107, 109, 111),
wherein, at the capsule filling station 105, 107, the support structure (114) is attached to the body engagement plate (112) is positioned in the gap (116) below the body plate (108) supported on the supporting portion (118) of the elevated support structure (106), wherein the support structure (114) is adapted to resist vertical and horizontal loads placed on the capsule bodies (208) during a capsule filling process.

22. The system (115) according to any of the preceding claims, wherein:
the magnetic mover (102) is adapted to be moved over the electromagnetic area (104) to a capsule recapping station 109 from among the plurality of stations (101, 103, 105, 107, 109, 111),
wherein, at the capsule recapping station 109, the cap engagement plate (122) engages with the cap plate (110) to resist the upward force applied by the body engagement plate (112) on the capsule bodies, the body engagement plate (112) applies the upward force via one of the engaging element (120) on each capsule body (208) in the body plate (108) such that the capsule cap (206) and the capsule body (208) are recapped to form the capsule,
wherein, at the capsule recapping station 109, the at least one support structure (114) is attached to the cap engagement plate (122), and is attached to the body plate (108) via the body plate holder (124) such that the support structure (114) distributes horizontal and vertical loads placed on the body plate (124) and the cap engagement plate (122), and resists a vertical and horizontal movement of the body plate (108) during a recapping process.

23. The system (115) according to claim 22, wherein the body engagement plate (112) is adapted to deliver a predefined amount of the upward force applied by the body engagement plate to the capsule bodies (208) to enable attachment of the capsule cap (206) with the capsule body (208)., wherein the predefined amount of the upward force applied by the body engagement plate (112) is at least 25 newtons.

24. The system (115) according to any of the preceding claims, wherein:
the magnetic mover (102) is adapted to be moved over the electromagnetic area (104) to a capsule ejection station 111 from among the plurality of stations (101, 103, 105, 107, 109, 111),
wherein the body engagement plate (112) applies the upward force via one of the engaging elements (120) on each capsule body (208) such that the capsule is ejected from the cap plate (110) and the body plate (108)

25. The system (115) according to claim 24, wherein the at least one support structure (114) is adapted to distribute loads exerted on the body plate (108) and the cap plate (108) when the body engagement plate (112) applies the upward force for ejecting the capsule, and resist a horizontal movement of the body plate (108) during a capsule ejection process.

26. The system (115) according to any of the preceding claims, wherein the magnetic mover (102) is configured to be indexed for moving the elevated support structure (106) to a plurality of predefined positions within each station.

27. The system (115) according to any of the preceding claims, wherein each of the at least one support structure (114), the elevated support structure (106), the body plate (108), the cap engagement plate (122), the body engagement plate (112), or the cap plate (122) is formed of a non-magnetic material.

28. The system (115) according to any of the preceding claims, wherein, particular recipe-based formulations for one of individual or batches of products are to be delivered within the capsule-filling manufacturing unit 100 and directed to at least one of the plurality of stations (101, 103, 105, 107, 109, 111).

29. The system (115) according to claim 28, wherein the body plate (108) is configured to be identified by a plurality of capsule filling stations 105, 107, from among the plurality of stations (101, 103, 105, 107, 109, 111), to determine a level of dosing to be applied, wherein the determined level of dosing is applied to the identified plates by the respective filling stations.

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