Abstract: A system for monitoring production of uniform strands, such as medical sutures, utilizes a measurement head through which the strand passes. The measurement head includes a plurality of light beams illuminating a corresponding number of sensors. The light beams all illuminate the same section of the strand as it travels through the measurement head. Passage of a fault through the light beams produces a fault signal, which is used by the production system to excise and discard the strand section including the fault. Synchronization and summing of the plurality of fault signals increases the sensitivity and accuracy of the system.

Abstract: A device for singulating surgical needles from a bulk supply of needles includes a vibratory bowl for receiving the supply of needles. The bowl has a floor to receive the needles, a track extending from the floor to a needle discharge point and a selectively vibrating motor to vibrate the surgical needles into a single file along the track. A discharge device has first and second needle receiving pockets, and positions the first and the second needle receiving pockets below the needle discharge point. A controller selectively vibrates the vibratory bowl and selectively positions the first and second needle pockets below the needle discharge point, the controller singulating individual needles from the single file of needles into the first and second needle receiving pockets. A discharger discharges the singulated needles in a spaced relationship on a conveyor for subsequent imaging at an inspection station.

Abstract: A method for cuffing suture, including: feeding the suture to a drawing axis for drawing and cutting thereof; heating the suture to stiffen a small length; gripping the suture and alternately drawing it along the drawing axis by first and second grippers; cutting the suture to provide uniform lengths; and providing a predetermined length of suture travel between the heating step and the cutting step, which is a discrete number, two or more, times the uniform length of suture being cut by the apparatus, to provide a discrete number, two or more, of apparatus cutting cycles between heating of the suture and cutting of the suture, whereby after heating of a small length of suture, the suture is cooled to allow setting and hardening of the suture material prior to cutting.

Abstract: A device for singulating surgical needles from a bulk supply of needles including a vibratory bowl assembly for receiving said bulk supply of needles. The bowl assembly having a floor to receive the needles, a track extending from the floor to a needle discharge point and a selectively vibrating motor to vibrate the surgical needles into a single file along the track; a discharge device having first and second needle receiving pockets, the device positioning the first and the second needle receiving pockets below said needle discharge point; a controller for selectively vibrating the vibratory bowl and selectively positioning the first and second needle pockets below the needle discharge point, the controller singulating individual needles from the single file of needles into the first and second needle receiving pockets; a discharger for discharging the singulated needles in the first and second needle pockets in a spaced relationship on a conveyor for subsequent imaging at an inspection station.

Abstract: A device for singulating surgical needles from a bulk supply of needles including a vibratory bowl assembly for receiving said bulk supply of needles. The bowl assembly having a floor to receive the needles, a track extending from the floor to a needle discharge point and a selectively vibrating motor to vibrate the surgical needles into a single file along the track; a discharge device having first and second needle receiving pockets, the device positioning the first and the second needle receiving pockets below said needle discharge point; a controller for selectively vibrating the vibratory bowl and selectively positioning the first and second needle pockets below the needle discharge point, the controller singulating individual needles from the single file of needles into the first and second needle receiving pockets; a discharger for discharging the singulated needles in the first and second needle pockets in a spaced relationship on a conveyor for subsequent imaging at an inspection station.

Abstract: Apparatus for cutting an indefinite length suture to uniform lengths for subsequent threading and swaging to surgical needles includes a drawing tower having first and second guide members defining a drawing axis parallel thereto. First and second grippers are provided to grip the indefinite length suture and to alternately draw it along the drawing axis, with each gripper being mounted for reciprocal movement along a guide member. Each gripper alternately grips the suture and draws it a distance beyond the location of a cutter assembly while the other gripper reciprocates to a start position before the cutter assembly. A tipping assembly heats a predetermined small length of the suture to stiffen the suture thereat after subsequent cooling, in preparation for cutting the suture and inserting a stiffened lead cut end of the suture into an end of a needle for swaging thereto.

Abstract: A semi-automated machine for preparing double-armed sutures, i.e., a suture with a surgical needle at either end of the suture, from a bulk supply of surgical needles and an indefinite length of suture material is described. Each of the surgical needles has a suture receiving opening formed therein for receiving a suture. The machine includes a needle singulation station, a precise positioning station, a suture feeding and cutting station, a swage station, a pull-test station and an off-load station. A universal gripper mounted on a rotary indexing device automatically receives each individual needle in a predetermined orientation and conveys the needle for sequential processing from station to station to form the needle-suture assembly. A suture drawing and cutting station automatically inserts an end of the indefinite length of suture into the first of the pair of needles that form the double-armed suture.

Abstract: Apparatus for cutting an indefinite length suture to different lengths for subsequent threading and swaging to surgical needles includes a drawing tower having first and second guide members defining a drawing axis parallel thereto. First and second grippers are provided to grip the indefinite length suture and to alternately draw it along the drawing axis, with each gripper being mounted for reciprocal movement along a guide member. Each gripper alternately grips the suture and draws it a distance beyond the location of a cutter assembly while the other gripper reciprocates to a start position before the cutter assembly. A tipping assembly heats a predetermined small length of the suture to stiffen the suture thereat after subsequent cooling, in preparation for cutting the suture thereat and inserting a stiffened lead cut end of the suture into an end of a needle for swaging thereto.

Abstract: Apparatus for cutting an indefinite length suture to different lengths for subsequent threading and swaging to surgical needles includes a drawing tower having first and second guide members defining a drawing axis parallel thereto. First and second grippers are provided to grip the indefinite length suture and to alternately draw it along the drawing axis, with each gripper being mounted for reciprocal movement along a guide member. Each gripper alternately grips the suture and draws it a distance beyond the location of a cutter assembly while the other gripper reciprocates to a start position before the cutter assembly. A tipping assembly heats a predetermined small length of the suture to stiffen the suture thereat after subsequent cooling, in preparation for cutting the suture thereat and inserting a stiffened lead cut end of the suture into an end of a needle for swaging thereto.

Abstract: A semi-automated machine and method for singulating individual surgical needles from an bulk supply and attaching a suture to the surgical needle is described. Each of the surgical needles has a suture receiving opening formed therein for receiving a suture. The machine includes a singulation station having a sliding surface that assists an operator in singulating needles and depositing them in a pair of drop locations for subsequent automatic handling. Indexing conveyors, an articulated robot and a precision conveyor are used with a precise positioning station for orienting each needle for automatic handling. A universal gripper mounted on a rotary indexing device automatically receives each individual needle in a predetermined orientation and conveys the needle for sequential processing from station to station to form the needle-suture assembly.

Abstract: A needle sorting device including an infeed device which first singulates a bulk supply of surgical needles into single file with an intermittently driven vibratory feed bowl assembly, and then individually separates and deposits the needles on a first conveyor for transmission to a processing station with a linear slide discharge mechanism. The first conveyor is translucent and during transit, one or more cameras obtain an image of the individual deposited needles. The image is digitized and the digital signals are transmitted to a control system computer which evaluates the position and orientation for needles and processes the information to obtain data for communication to one or more robot assemblies having grippers. Utilizing the position and orientation data, the robot assembly grippers removes selected needles from the first conveyor and transfers each needle to an engagement device located upon a second precision conveyor.

Abstract: A control system for a needle singulation and infeed apparatus that automatically picks up surgical needles in random, un-oriented positions on a transport conveyor or like device, and places them in oriented positions for suture attachment at a fully automated needle swaging station. The apparatus employs one or more robot devices for picking up the needles and placing them in individual precision engagement devices for sequential conveyance to an automatic swaging machine. After gripping the needle, and, depending upon the orientation of the needle with respect to the robot gripper, the robot gripper can pick the needle and move to a location where a mechanical finger is fixedly positioned. The robot is programmed to move to the mechanical finger and tap the needle held by the robot gripper against the finger to orient or rotate the needle in the proper direction prior to placing the needle in the precision engagement device.

Abstract: A method for automatically forming armed surgical needles and for automatically packaging the same in a packaging tray, the automatic forming and packaging operating under control of a control computer, each armed surgical needle including a surgical needle having a suture receiving opening formed therein for attachment of a definite length suture material thereof.

Abstract: A needle sorting device includes an infeed device which first singulates a bulk supply of surgical needles into single file with an intermittently driven vibratory feed bowl assembly, and then individually separates and deposits the needles on a first conveyor for transmission to a processing station with a linear slide discharge mechanism. The first conveyor is translucent and during transit, one or more cameras obtain an image of the individual deposited needles. The image is digitized and the digital signals are transmitted to a control system computer which evaluates the position and orientation for needles and processes the information to obtain data for communication to one or more robot assemblies having grippers. Utilizing the position and orientation data, the robot assembly grippers removes selected needles from the first conveyor and transfers each needle to an engagement device located upon a second precision conveyor.

Abstract: Apparatus for cutting an indefinite length suture to uniform lengths for subsequent threading and swaging to surgical needles includes a drawing tower having first and second guide members defining a drawing axis parallel thereto. First and second grippers are provided to grip the indefinite length suture and to alternately draw it along the drawing axis, with each gripper being mounted for reciprocal movement along a guide member. Each gripper alternately grips the suture and draws it a distance beyond the location of a cutter assembly while the other gripper reciprocates to a start position before the cutter assembly. A tipping assembly heats a predetermined small length of the suture to stiffen the suture thereat after subsequent cooling, in preparation for cutting the suture thereat and inserting a stiffened lead cut end of the suture into an end of a needle for swaging thereto.

Abstract: The present invention is directed to improvements in an Automated Swage Wind and Packaging Machine that is particularly adapted to assist in the automated singulation of surgical needles to enable subsequent automated handling of the needle, automatic swaging of the suture into a receiving end of the needle, automatic pull testing of the combined needle and suture, and automated packaging of the pull tested combined needle and suture into a tray having a cover.

Abstract: A semi-automated machine for singulating individual surgical needles from an bulk supply and attaching a suture to the surgical needle is described. Each of the surgical needles has a suture receiving opening formed therein for receiving a suture. The machine includes a singulation station having a sliding surface that assists an operator in singulating needles and depositing them in a pair of drop locations for subsequent automatic handling. Indexing conveyors, an articulated robot and a precision conveyor are used with a precise positioning station for orienting each needle for automatic handling. A universal gripper mounted on a rotary indexing device automatically receives each individual needle in a predetermined orientation and conveys the needle for sequential processing from station to station to form the needle-suture assembly.

Abstract: A machine for the automated packaging of armed sutures or; in effect, surgical needles having sutures attached thereto and, more particularly, a needle gripper and transfer arrangement in an automated machine for the high-speed individualized packaging into trays of single or individual surgical needles each having an attached suture and a detachable cover providing a suture package utilized for the packaging of the individual or single needles and attached sutures. The machine includes vertically adjustable frame structure so as to adjust the elevation thereof relative to the needle transfer arrangement to facilitate the packaging of differently sized needles in a single size of packaging tray.

Abstract: A machine and a method for the automated packaging of armed sutures or; in effect, surgical needles having sutures attached thereto and, more particularly, an automated machine for the high-speed individualized packaging of single or individual surgical needles each having an attached suture into a tray and detachable cover providing a suture package utilized for the packaging of the individual or single needles and attached sutures. Additionally, the automated packaging machine incorporates operative mechanism adapted to wind the sutures into a peripheral channel of the tray and facilitating the attachment of the cover to the tray which contains the single needle and attached wound suture, and which cover concurrently constitutes a product-identifying label as a component of the tray, and upon removal of the cover enables a user to gain access to the contents of the tray; in essence, the armed suture.

Abstract: A machine for the automated packaging of armed sutures or; in effect, surgical needles having sutures attached thereto and, more particularly, a suture winding arrangement in an automated machine for the high-speed individualized packaging of single or individual surgical needles each having an attached suture into a tray and detachable cover providing a suture package utilized for the packaging of the individual or single needles and attached sutures.