U.S. patent application number 09/860204 was filed with the patent office on 2001-10-11 for integrated automated drug dispenser method and apparatus.
This patent application is currently assigned to AutoMed Technologies, Inc.. Invention is credited to Hebron, Terrance J., Vandy Bogurt, Douglas L..
Application Number | 20010027634 09/860204 |
Document ID | / |
Family ID | 26794187 |
Filed Date | 2001-10-11 |
United States Patent
Application |
20010027634 |
Kind Code |
A1 |
Hebron, Terrance J. ; et
al. |
October 11, 2001 |
Integrated automated drug dispenser method and apparatus
Abstract
A system is provided for automatically dispensing prescriptions
according to a patient's order. The system includes at least one
line of machines that can automatically fill a patient's
prescription order with countable oral solid medication under the
control of an appropriate control system. The system includes
containers provided to store the oral solid medication. One or more
medication-containing containers are detachably coupled to a
vibratory dispenser according to a patient's order. The vibratory
dispenser automatically vibrates the container to dispense a
predetermined amount of medication from the container into the vial
according to the patient's order. Labeling and capping apparatus
may be provided to apply a patient-specific label to the vial and
to apply a cap or closure to the vial. Vials containing medication
according to the patient's order may be collected in accumulation
receptacles prior to delivery to a patient.
Inventors: |
Hebron, Terrance J.;
(Antioch, IL) ; Vandy Bogurt, Douglas L.; (Grand
Haven, MI) |
Correspondence
Address: |
JANSSON, SHUPE & MUNGER, LTD
245 MAIN STREET
RACINE
WI
53403
US
|
Assignee: |
AutoMed Technologies, Inc.
|
Family ID: |
26794187 |
Appl. No.: |
09/860204 |
Filed: |
May 18, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09860204 |
May 18, 2001 |
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09209995 |
Dec 11, 1998 |
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6256967 |
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60098124 |
Aug 27, 1998 |
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Current U.S.
Class: |
53/501 |
Current CPC
Class: |
G06Q 10/087 20130101;
B65B 57/20 20130101; B65B 5/103 20130101; G07F 11/44 20130101; G07F
17/0092 20130101; G07F 17/0042 20130101 |
Class at
Publication: |
53/501 |
International
Class: |
B65B 005/08; B65B
057/20 |
Claims
What is claimed is:
1. Apparatus for automatically filling prescription orders for oral
solid medication in accordance with patient-specific prescription
order information comprising: a controller for receiving the
patient-specific prescription information and for controlling
prescription filling apparatus for filing the prescription order; a
plurality of oral solid medication containers for containing oral
solid medication therein; at least one vibratory dispenser
operatively controlled by the controller and including a coupling
for attachment of an oral solid medication container in a
detachable relationship, the dispenser providing vibration to a
coupled container in response to the prescription information so
that medication is dispensed from the container into a vial; at
least one container transport assembly operatively controlled by
the controller for automatic transport of an oral solid medication
container between a container storage location and the vibratory
dispenser in response to the prescription information; and a vial
transport assembly operatively controlled by the controller for
automatic transport of empty vials to the vibratory dispenser and
filled vials to at least one predetermined location in response to
the prescription information; whereby the filled prescription order
is collected in at least one predetermined location.
2. The prescription filling apparatus of claim 1 wherein the
predetermined location is an accumulator and the filled vials
according to a patient-specific prescription order are transported
to the accumulator for collection.
3. The prescription filling apparatus of claim 1 further including
a vial labeler positioned with respect to a vial for applying a
label to the vial.
4. The prescription filling apparatus of claim 3 further including
a vial capper positioned with respect to a filled vial for capping
the vial.
5. The prescription filling apparatus of claim 1 wherein the oral
solid medication containers are canisters comprising: a canister
body having a bottom wall, at least one sidewall and inner and
outer canister surfaces, at least one wall defining a discharge
opening through which the oral solid medication is discharged from
the canister and the at least one sidewall defining an opening
through which medication is loaded into the canister; medication
separation structure positioned with respect to the canister inner
surface, the separation structure having a first end for receiving
oral solid medication from the canister, a second end in
communication with the discharge opening and a separation surface
therebetween on which the medication is transported along the
surface to the discharge opening; and a coupling mechanism attached
to the canister for detachably coupling the canister to the
vibratory dispenser.
6. The prescription filling apparatus of claim 5, wherein the
separation surface is of a predetermined width so as to cause the
medication to be arranged in a substantially single row.
7. The prescription filling apparatus of claim 5 further including:
a frame positioned with respect to the container transport
assembly; and a plurality of canister storage shelves along the
frame, each shelf for storing at least one canister.
8. The prescription filling apparatus of claim 1 wherein the
container is a canister and the coupling is a quick coupling
mechanism attaching the canister to the vibratory dispenser and
permitting rapid coupling and decoupling of the canister from the
dispenser.
9. The prescription filling apparatus of claim 8, wherein the quick
coupling mechanism comprises: a magnet attached to the vibratory
dispenser; and a magnetically-attractive member attached to the
canister; whereby, the canister is detachably coupled to the
vibratory dispenser by the action of the magnet and the
magnetically-attractive member.
10. The prescription filling apparatus of claim 1 wherein the
vibratory dispenser includes: at least one drive unit for vibrating
an oral solid medication container mounted thereon; a coupling
mechanism attached to the vibratory dispenser for detachably
coupling the oral solid medication container to the drive unit; and
a sensor positioned in an oral solid medication dispensing path,
the sensor registering a count when the dispensed oral solid
medication passes the sensor.
11. The prescription filling apparatus of claim 10, wherein the
coupling mechanism is a magnet secured with respect to the drive
unit designed for mating with a magnetically-attractive member
positioned on the oral solid medication container.
12. The prescription filling apparatus of claim 10 wherein the
vibratory dispenser vibrates the oral solid medication container by
varying an amplitude component of the vibration.
13. The prescription filling apparatus of claim 10 wherein the
vibratory dispenser vibrates the oral solid medication container by
varying a frequency component of the vibration.
14. The prescription filling apparatus of claim 10 further
including: a comparator for comparing the amount of dispensed
medication to the amount of medication to be dispensed including a
comparison at a vial filling cycle end period; and if the
comparison at the vial filling cycle end period shows that less
than all of the medication has been dispensed, the controller
causes the vibratory dispenser to provide at least one vibratory
pulse to dispense any remaining medication from the oral solid
medication container.
15. The prescription filling apparatus of claim 10 wherein the
container transport assembly comprises: a drive mechanism for
positioning the assembly to grip an oral solid medication
container; and a gripper assembly coupled to the drive mechanism
for gripping an oral solid medication container.
16. The prescription filling apparatus of claim 15 wherein the
drive mechanism comprises: a plurality of guides arranged in an
orthogonal coordinate system; and a motor for moving the assembly
along the guides.
17. The prescription filling apparatus of claim 16 wherein the
gripper assembly comprises: at least two generally opposed fingers
moveable between an open, release position and a closed, gripping
position; a rotatable cam operatively connected to the fingers for
opening and closing the fingers; and at least one limit switch for
sensing whether the fingers are in the opened or closed
positions.
18. The prescription filling apparatus of claim 17 further
including a motor for rotating the cam.
19. The prescription filling apparatus of claim 1 wherein the vial
transport assembly is the container transport assembly.
20. A system for dispensing oral solid medication from a canister
containing the medication comprising: means for detachably coupling
the canister to a vibrating means; means for vibrating a canister
detachably coupled to the vibrating means, said vibration causing
oral solid medication to be dispensed from the detachably coupled
canister; and means for controlling vibration frequency of the
vibrating means to cause the medication to be dispensed from the
detachably coupled canister in a predetermined manner.
21. The system of claim 20 further comprising means for controlling
vibration amplitude of the vibrating means to cause the medication
to be dispensed from the canister in a predetermined manner.
22. The system of claim 20 further comprising means for comparing
the amount of dispensed medication to a total amount of oral solid
medication to be dispensed.
23. The system of claim 22 wherein the vibration frequency provided
by the vibrating means is changed as the numerical difference
between the amount of medication to be dispensed and the amount of
medication actually dispensed changes.
24. The system of claim 23 wherein the vibration amplitude provided
by the vibrating means is changed as the numerical difference
between the amount of medication to be dispensed and the amount of
medication actually dispensed changes.
25. A system for dispensing prescription oral solid medication from
a bulk storage canister containing the medication comprising: a
vibratory dispenser for vibrating a medication-containing canister
detachably coupled to the vibratory dispenser during dispensing of
the oral solid medication; a coupling mechanism for rapid coupling
and decoupling of the canister from the vibratory dispenser; and a
controller for controlling the vibratory dispenser so that the
vibratory dispenser vibrates the canister at a predetermined
frequency.
26. The system of claim 25 wherein the vibratory dispenser further
comprises a mechanism for counting dispensed oral solid
medication.
27. The system of claim 26 wherein the counting mechanism further
comprises a sensor that registers a count when the dispensed oral
solid medication passes the sensor.
28. The system of claim 27 wherein the count is cumulative.
29. The system of claim 28 wherein the count is compared to a total
count to be dispensed thereby providing an instantaneous count of
the total amount of dispensed medication.
30. The system of claim 25 wherein the controller further includes
a shutter positioned along a medication dispensing path, the
shutter interposing a light source, and a photodetector spaced from
the shutter for receiving the light.
31. The system of claim 25 wherein the vibratory dispenser further
comprises at least one drive unit.
32. The system of claim 31 wherein the coupling device comprises: a
magnet attached to the drive unit; and a magnetically-attractive
member attached to the canister; whereby, the canister is
detachably coupled to the drive unit by the action of the magnet
and the magnetically-attractive member.
33. The system of claim 25 wherein the vibratory dispenser vibrates
the canister by varying an amplitude component of the
vibration.
34. The system of claim 25 wherein the vibratory dispenser vibrates
the canister by varying the frequency component of the vibration
and the vibration of the canister is correlated to a medication
count and to a total count which represents the total amount of the
medication to be dispensed.
35. The system of claim 34 wherein the vibration frequency is
changed as the medication count nears the total count.
36. The system of claim 34 wherein the vibratory dispenser vibrates
the canister based on a preset frequency selected from a table of
frequencies.
37. The system of claim 34 wherein the drive unit vibrates the
canister based on a feedback control that measures the frequency of
vibration and adjusts the frequency based on the count.
38. The system of claim 33 wherein the vibratory dispenser vibrates
the canister by varying the amplitude component of the vibration
and the vibration of the canister is correlated to a medication
count and to a total count which represents the total amount of
medication that is to be dispensed.
39. The system of claim 38 wherein the vibration amplitude is
changed as the medication count nears the total count.
40. The system of claim 38 wherein the drive unit vibrates the
canister based on a preset amplitude selected from a table of
amplitudes.
41. The system of claim 38 wherein the drive unit vibrates the
canister based on a feedback control that measures the amplitude of
vibration and adjusts the amplitude based on the count.
42. The system of claim 25 wherein the canister comprises: a
canister body having a bottom wall, at least one sidewall and inner
and outer canister surfaces, at least one wall defining a discharge
opening through which the oral solid medication is discharged from
the canister and the at least one sidewall defining an opening
through which medication is loaded into the canister; medication
separation structure positioned with respect to the canister inner
surface, the separation structure having a first end for receiving
oral solid medication from the canister, a second end in
communication with the discharge opening and a separation surface
therebetween on which the medication is transported along the
surface to the discharge opening; and a coupling mechanism attached
to the canister for detachably coupling the canister to the
vibratory dispenser.
43. The system of claim 42 wherein the medication separation
structure comprises: an upwardly sloping helical ramp positioned
about the canister inner surface; the first end is a ramp first end
along a bottom surface of the canister; and accelerator structure
having one end in communication with a ramp upper end another end
in communication with the discharge opening and a surface
therebetween, the surface including a downwardly sloping portion
facilitating separation of medication within the canister.
44. The system of claim 42 wherein the canister further comprises a
stop positioned with respect to the discharge opening, the stop
having a first position preventing medication from being dispensed
and a second position allowing medication to be dispensed through
the opening.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent
application Ser. No. 09/209,995 filed Dec. 11, 1998, now U.S. Pat.
No. ______, which is a continuation of U.S. Provisional Patent
Application Ser. No. 60/098,124 filed Aug. 27, 1998 now abandoned.
The content of such applications is hereby incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to automated devices for
selecting, filling and capping vials of prescription drugs and
dispensing unit-of-use prescription drugs within the same device
according to a patient specific order.
BACKGROUND OF THE INVENTION
[0003] Generally, patients have been provided with prescriptions in
one of two ways. One way is to provide prescriptions that are
pre-filled in vials ("unit-of-use drugs") at a remote location and
kept in inventory at a pharmacy. These unit-of-use drugs are
removed from stock when needed and relabeled with patient specific
information. Another method involves filling prescriptions by
having a pharmacist hand-dispense the required drugs from a bulk
supply and then place a patient specific label on a vial.
[0004] There are disadvantages to both of these
prescription-filling methods. If pharmacists elect to use
unit-of-use drugs, they must carry an inventory of several hundred
drug types. Furthermore, they must manage inventory levels and
monitor stock for expiring products. Generally, a pharmacist will
pay a premium for having the drugs pre-packaged.
[0005] On the other hand, filling prescriptions from bulk on an
individual basis is very labor intensive and subject to human
accounting errors. Further, servicing a large patient population
requires large numbers of pharmacists.
[0006] Automated prescription-filling apparatus are available that
count oral solid prescriptions. In one patented device, drugs are
stored in bulk storage canisters in rotary dispenser lines that
dispense the drugs. Drugs are dispensed from the canisters into
vials. The canister is keyed to a specific storage position within
such a device by a mechanical pin arrangement. Provisions are made
in the event there is an inability to fill a prescription or order.
Once filled, all of the patient's prescriptions are collected and
made available as a single order.
[0007] In another available apparatus, single countable drugs are
automatically and repetitively counted. However, there is no
provision in this type of apparatus for placing the drugs in vials.
Other apparatus fill prescriptions from a supply of unit-of-use
drugs.
[0008] In the retail pharmacy market, in particular, there is a
noted lack of devices that would serve to automate the prescription
filling process. The devices described above work well within the
limited field of use each afford. However, no products presently on
the market can both retrieve, count and dispense a variety of oral
solid drugs in the retail setting.
[0009] State-of-the-art automated prescription dispensing apparatus
possess several disadvantages. These apparatus do not provide for
the dispensing of countable drugs and unit-of-use drugs in the same
device. These apparatus do not use machine-readable information to
identify a canister with a specific location within the apparatus,
thus assuring the return of a canister to the proper location
without operator intervention. These apparatus do not optimize the
location of a canister within the apparatus based on the frequency
of drug use.
SUMMARY OF THE INVENTION
[0010] The present invention provides an improved method and
apparatus for dispensing prescriptions. The invention eliminates
the need for two apparatus to dispense countable solid oral drugs
and unit-of-use drugs. The invention provides an improved method
for identifying drugs and the drugs' location in the apparatus. The
invention further provides an improved method of dispensing drugs
into patient accessible containers. The invention still further
provides a positive method for preventing over counting of oral
solid drugs. To these ends, the invention provides an improved
automated prescription filling system.
[0011] In an embodiment, the invention provides a system whereby a
pharmacist inputs a patient's order including prescription
information, National Drug Code ("NDC") number, and patient
identification information via a computer terminal. The system
processes the information and automatically fills one or more vials
with one or more drugs, and then automatically labels and caps the
vials containing drugs, pursuant to the pharmacist's order. The
system processes the information and also automatically dispenses
one or more unit-of-use drugs, if ordered. The order is accumulated
in a patient receptacle and presented to the pharmacist as the
patient's complete order, ready for pick-up or delivery.
[0012] In an embodiment, the invention provides that a system for
accompanying the foregoing consists of at least one line of
machines that will automatically fill, label, cap, and sort vials
of different sizes with one or more prescriptions in accordance
with a patient order. This same machine will dispense unit-of-use
drugs. Patient prescriptions are accumulated in a patient specific
receptacle.
[0013] In an embodiment, the invention provides a system whereby
countable solid oral drugs are dispensed from multiple canisters,
in which the drugs are stored in bulk, into vials for delivery to
the patient. Means are provided to prevent over counting drugs.
[0014] In another embodiment, the invention provides an improved
apparatus for automatically gripping the canisters. Means are
provided for gripping, manipulating and releasing canisters in a
system designed to automatically dispense prescription drugs.
[0015] In yet another embodiment, the invention provides a method
of optimizing canister location. A method is provided by which the
canisters are ordered according to the their level of use.
[0016] Located at an end of the dispensing line are accumulation
receptacles. The accumulation receptacles are used to accumulate a
patient's complete order for pickup or delivery. An advantage of
the invention is the ability to more efficiently employ technicians
and pharmacists for dispensing drugs. Another advantage of the
invention is the automation of dispensing a great majority of
otherwise hand-picked items, thus freeing up the pharmacist for
greater patient interaction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIGS. 1A, 1B and 1C are schematics for a system in
accordance with the principles of the present invention.
[0018] FIGS. 2A, 2B and 2C are schematics for a canister gripper in
accordance with the principles of the present invention.
[0019] FIG. 2D is a schematic of an unscrambler in accordance with
the principles of the present invention.
[0020] FIGS. 3A and 3B are schematics for a canister in accordance
with the principles of the present invention.
[0021] FIG. 4 is a schematic for a unit-of-use bin in accordance
with the principles of the present invention.
[0022] FIG. 5 is a flow diagram for the method of the system of
FIG. 1.
[0023] FIG. 6 is a flow diagram for the prescription fill method of
the system of FIG. 1.
[0024] FIG. 7 is a flow diagram for the prescription-sort method of
the system of FIG. 1.
[0025] FIG. 8 is a flow diagram for a patient entry process in
accordance with the principles of the present invention.
[0026] FIG. 9 is a flow diagram for a patient fill process in
accordance with the principles of the present invention.
[0027] FIG. 10 is a flow diagram for a process for assignment of
prescriptions to a filling line in accordance with the principles
of the present invention.
[0028] FIGS. 11 and 12 are flow diagrams for a process for
selection and assignment of accumulation receptacles in accordance
with the principles of the present invention.
[0029] FIG. 13 is a flow diagram for a refill process in accordance
with the principles of the present invention.
[0030] FIG. 14 is a flow diagram for a prescription fill process in
accordance with the principles of the present invention.
[0031] FIG. 15 is a flow diagram for a check filling line process
in accordance with the principles of the present invention.
[0032] FIG. 16 is a flow diagram for an unscrambler check process
in accordance with the principles of the present invention.
[0033] FIG. 17 is a flow diagram for a labeler check process in
accordance with the principles of the present invention.
[0034] FIG. 18 is a flow diagram for a vibratory dispenser check
process in accordance with the principles of the present
invention.
[0035] FIG. 19 is a flow diagram for a capper check process in
accordance with the principles of the present invention.
[0036] FIG. 20 is a flow diagram for a line scanner check process
in accordance with the principles of the present invention.
[0037] FIG. 21 is a flow diagram for an accumulator check process
in accordance with the principles of the present invention.
[0038] FIG. 22 is a flow diagram for a staging input process in
accordance with the principles of the present invention.
[0039] FIG. 23 is a flow diagram for a prescription sort process in
accordance with the principles of the present invention.
DETAILED DESCRIPTION
[0040] In accordance with the invention, a system is provided for
dispensing prescriptions, preferably for outpatients, wherein the
system packages an order of one or more prescriptions in view of
patient prescription information and then presents a complete
patient's order to a pharmacist for pick-up or delivery. In
accordance with the principles of the present invention, a system
is illustrated in FIGS. 1-4. Flow diagrams for the methods of such
a system are illustrated in FIGS. 5-7. Processes employed in the
system are described below.
[0041] As illustrated in FIG. 1, a system 100 is provided which
includes at least one line 105 of machines that can automatically
fill, label, cap, and sort vials in accordance with a patient's
prescription order under the control of an appropriate control
system. While one line is depicted in the illustrated embodiment,
the present invention encompasses any number of lines. The
apparatus of the invention includes numerous components that are
integrated into a singular process. These components are described
in further detail.
[0042] Robotic Pick-and-Place Unit. Central to the system 100 is a
robotic pick-and-place unit 140 ("robotic assembly") that is used
to manipulate and transport vials, canisters, and bins, as further
described below, within the system. The robotic assembly 140
includes a drive mechanism that moves a gripper assembly 20 along
any axis of an orthogonal coordinate system (e.g. the x, y or z
axes). The drive mechanism typically includes means for moving the
gripper assembly along a plurality of tracks, rails, screws or
guides that are oriented along the x, y and z axes of an orthogonal
coordinate system. The movement means may include an electric
motor, a pneumatic motor, a servo mechanism, or other means for
moving the gripper assembly. A controller 180 controls the
positioning of the robotic assembly 140, and thus the gripper
assembly 20 and the operation of the gripper assembly 20. In this
way the gripper assembly is positioned to pick a vial, canister or
bin. Vials, canisters or bins are picked by the action of the
gripper assembly 20 grasping these objects, lifting them from the
rest position and transporting them to a new rest position.
[0043] While only one robotic assembly 140 may be used to pick and
place vials, canisters, and bins, it is also envisioned that more
than one robotic assembly 140 may be used. For example, one robotic
assembly 140 may be used for each class of items to be picked and
placed. Preferably, one robotic assembly 140 is used to pick and
place vials, while another robotic assembly 140 is used to pick and
place bins and canisters. Where more than one robotic assembly 140
is used, the robotic assemblies may act simultaneously in
performing the assigned function.
[0044] Gripper Assembly. The gripper assembly 20 includes means
which are actuated to grasp objects. Preferably, the gripper
assembly 20 includes movably opposed fingers and means for moving
the fingers together and for separating the fingers. The movement
means includes air cylinders that are double acting in that
compressed air is applied to the cylinder to move the arms together
and then to separate the fingers. More than one air cylinder may be
used. However, preferably, a spring may be used to replace the
action of an air cylinder in either moving the fingers together or
in separating the fingers. It is also anticipated that more than
one gripper assembly may be employed in a system made according to
the principles of the present invention.
[0045] An embodiment of a gripper assembly 20 made in accordance
with the principles of the present invention is depicted in FIGS.
2A and 2B. The gripper assembly 20 includes flexible, or compliant,
fingers 21, 22 that are generally opposed. A rotary cam 26 operates
to move the fingers 21, 22 towards each other, and a spring 23 is
used to return the fingers to an open position when the fingers are
not being actuated by the rotary cam 26. Means 24 are provided to
rotate the cam 26. Typically, the rotating means include an
electric motor, but an air driven motor, or solenoids, either air
or electric actuated, may be used. The gripper assembly 20 has a
simple open/close action. The opened or closed position of the
fingers 21, 22 are sensed by limit switches 27 and 28 that are
positioned to contact the cam 26. Alternately, the limit switches
27, 28 can be positioned to contact the fingers 21, 22,
respectively. As the cam 26 rotates, and based on the shape of the
cam, the cam will push the fingers 21, 22 to the closed position. A
limit switch 27 contacting the cam 26 will similarly be pushed
closed. When the cam 26 rotates to release the fingers 21, 22, the
fingers 21, 22 are returned to the opened position by the spring
24. The limit switch 28 contacting the cam 26 will similarly be
allowed to open. When the limit switch opens or closes, an
electrical signal is provided to a controller thus registering the
opened or closed status of the gripper assembly fingers 21, 22. An
alternate embodiment of a gripper assembly 20 made in accordance
with the principles of the present invention is depicted in FIG.
2C.
[0046] The gripper assembly of the present invention has many
advantages over prior art devices. For example, the gripper
assembly of the present invention prevents crushing of gripped
objects. Also, the gripper assembly of the present invention
prevents the bum out of the gripper assembly motor.
[0047] Vial Unscrambler. The first machine position in the system
100 is a vial unscrambler 110. In such a machine vials are dumped
into a hopper 150 in bulk form. The hopper 150 preferably is large
enough to hold a quantity of vials, ranging from about one hundred
to several hundred, or more. Multiple hoppers 150 may be used for
each vial size used, if more than one vial size is required.
[0048] The unscrambler 110 orients a vial upright in a separator
and places the vial in a pickup area ready to be picked by the
robotic assembly 140 and moved to a labeler 170. The unscrambler
110 can also be equipped to shoot a blast of air in the vial,
cleaning debris that might be present. The unscrambler 110 includes
a machine similar to an Omega Model number 20-LP manufactured by
Omega Design Corporation, 211 Philips Road, Lionville, Pa., or a
New England Machinery Model NEHE-50J or NEIHB-50AJ manufactured by
New England Machinery, Inc., 6204 29th Street East, Bradenton, Fla.
Generally, the unscrambler 110 prepares the vials for the next step
in the process of dispensing prescriptions.
[0049] An alternate unscrambler 110 is illustrated in FIG. 2D. The
unscrambler 110 includes storage means, release means, and
orientation means. Storage means includes a tube 151 which stores
vials in a horizontal position. Release means includes a moveable
pin 156 which serves to hold a vial at the bottom of the tube 151
and release the vial from the bottom of the tube 151 upon movement
of the pin 156. Alternately, the pin 157 may be replaced by a rod
or bar. Orientation means includes a dual chute arrangement having
a first chute 154 and a second chute 158. Each chute 154, 158 has
an opening 154a, 158a, respectively, through which a vial may pass.
The opening 154a is sized such that a vial must be in a near
vertical orientation before the vial can pass through the opening
154a. The opening 158a is sized to be larger than the opening
154a.
[0050] Additionally, vials may be placed into a device which
provides storage and delivery means in an orientation that requires
no further unscrambling. In such a device, unscrambling of vials is
accomplished by an operator who places the vials into the device in
a properly oriented position. Storage and delivery means may
include, for example, a tube which allows for a vertical stacking
of vials such that a vial may be placed into the top of the tube in
an oriented position and subsequently removed from the bottom of
the tube in the oriented position.
[0051] Vial Labeler. After unscrambling, the vial is labelled by a
label machine 170 ("labeler"), such as Avery Model ALX 910
available from Avery 65 Label Division, 35 McLachlan Drive,
Rexdale, Ontario, Canada or Willett Model 2600 manufactured by
Willett America, Inc., 4901 Northeast Parkway, Fort Worth, Tex. The
labeler 170 is located upstream of the vibratory dispenser 190 as
shown, or it can be located under the vibratory dispenser 190 to
label vials during or preferably immediately prior to filling. The
labeler 170 prints human readable information, as well as bar code
information on demand. The label information is kept in a database
and contains drug description, as well as any warning statements.
After the label is printed a reader can be provided associated with
the labeler 170, to verify the contents of the label by reading the
printed bar code. It is preferred that only after reading the
barcode will a process for filling prescriptions of the present
invention be allowed to proceed to the next step in the
process.
[0052] Canister. The canister used in the invention aids
integration of the other apparatus features with the methods for
dispensing prescription drugs. The canister may be of any suitable
design that allows dispensing of countable oral solid drugs within
an automated drug dispensing system. The canister may include a
label used to identify the contents of the canister.
[0053] A canister 130 made in accordance with the principles of the
present invention is illustrated in FIG. 3. The canister 130 is
preferably an assembly of components that includes a bowl 131, lid
132, an optional funnel 133, gate 134, an optional ramp lid 135,
and washer 136. The canister 130 is designed with an internal
vertical acceleration ramp 137 to facilitate separation of solid
drugs within the canister 130. This design allows gravity to
accelerate the movement of the drugs to a rate faster than the
transport rate of the canister 130 from the canister's storage
location to a vibratory dispenser 190 and thus creates a greater
distance interval between drugs. As the canister 130 is being moved
from the canister's storage location, momentum will move the drug
up the acceleration ramp 137 and gravity will accelerate the drug
down the end of the acceleration ramp 137. The acceleration ramp
137 may extend part-way around the circumference of the canister
130, or it extends several times around the circumference in a
spiral fashion. The drug then continues down a dispensing ramp 138
to the gate 134. The optional ramp lid 135 covers the dispensing
ramp 138 and prevents a drug from moving onto the dispensing ramp
138 by a path other than the path described above. Alternately, the
dispensing ramp 138 may be provided with a side wall that is
extended perpendicular to the plane of the dispensing ramp 138 and,
thus, will prevent a drug from prematurely moving onto the
dispensing ramp 138.
[0054] The preferred canister 130 provides singulation control to
the movement of drugs through the canister 130 and out the gate
134. Singulation control is the process by which drugs move through
the canister 130 in a nearly single-file fashion. Means for
singulation control is provided by the width of the acceleration
ramp 137 and the dispensing ramp 138. By providing the proper ramp
width, the movement of drugs in other than a nearly single-file
fashion is prevented. The proper ramp width may in fact be more
than one width and may, for example, be a width that is tapered
from a largest width to a smallest width. It may also be preferable
to design canisters for specific drugs based on the drug size and
shape. The drug size and shape may be used to select a proper ramp
width. Singulation control may be aided by maintaining the
acceleration ramp 137 and the dispensing ramp 138 surfaces on which
drugs move at an angle with respect to horizontal. The angle is
selected so that the edge of the ramp surface closest to the center
of the canister 130 is above a horizontal plane which intersects
the edge of the ramp surface farthest from the center of the
canister 130.
[0055] In order to positively retain solid drugs in the canister
130, while it is transported by the robotic assembly 140 to and
from the canister's storage location, the gate 134 is closed and
fixedly held to remain in a closed position while the canister 130
is in motion or is being stored. The gate 134 can be closed when
the total count is reached to prevent further solid drugs from
falling into the vial. It will not be opened until the counting
mechanism is activated so that any solid drugs on the gate 134 will
be counted into the vial accurately. The gate 134 may include, for
example, a shutter covering an exit hole, a horizontally operated
gate, or a vertically operated gate. As an alternative to closing
the gate quickly to prevent an extra drug from falling into the
vial, an air jet can separately be used to push the tablet that
would raise the drug count to one more than the total count back
from the gate into the canister. The air jet comprises an air
nozzle and an electrically activated valve assembly.
[0056] Unit-of-use Bin. The unit-of-use bin 145 used in this
invention may be of any suitable design that allows dispensing of
pre-packaged unit-of-use drugs within an automated drug dispensing
system. The unit-of-use bin 145 may include a label used to
identify the contents of the bin. Alternately, the label used to
identify the contents of a bin may be positioned on the dispensing
system 100 at the place of unit-of-use bin 145 storage. Such a
labeling procedure provides dynamic location control and allows the
placement of any unit-of-use drug in any unit-of-use bin 145.
[0057] A preferred unit-of-use bin 145 made in accordance with the
principles of the present invention is illustrated in FIG. 4. The
unit-of-use bin 145 provides a means to store and dispense
pre-packaged drugs. The unit-of-use bin 145 is designed to hold one
package of a pre-packaged drug. The unit-of-use bin 145 includes an
open end 147, a closed end 149, and bosses 146,148. The open end
147 of the unit-of-use bin 145 provides easy access to refill the
unit-of-use bin 145 with a single package of a prepackaged drug.
The gripper assembly 20 of the robotic assembly grasps the
unit-of-use bin 145 at the bosses 146, 148. In this way, the
unit-of-use bin 145 is transported from the unit-of-use bin's 145
storage location to an accumulation receptacle 165 in a process
that will be further described below. The contents of the
unit-of-use bin 145 may be transferred to the accumulation
receptacle 165 by scraping the contents, dumping the contents, or
vibrating the contents of the unit-of-use bin 145 into the
accumulation receptacle 165.
[0058] Dispensing Countable Oral Solid Drugs. From the labeler 170,
the robotic assembly 140 transports a vial to the vibratory
dispenser 190. Preferably, the robotic assembly 140 selects and
retrieves canisters 130 containing oral solid drugs. The robotic
assembly 140 further includes a gripper assembly 20 that grips the
canister 130 during the process of moving the canister 130 from a
storage position to an engagement position with the vibratory
dispenser 190. As described above, it is anticipated that more than
one robotic assembly 140 may be used in the system 100.
[0059] The vibratory dispenser 190 further includes at least one
drive unit, which couples to the canister 130 via a quick coupling
mechanism. The quick coupling mechanism further includes, for
example, mechanical latches, magnetic couplings, or electromagnetic
couplings which provide the means by which the canister fixedly
attaches to the drive unit.
[0060] The vibratory dispenser 190 still further comprises a
counting mechanism. The counting mechanism comprises a sensor that
registers when a solid oral drug is in the sensor's path. The
registration of a drug is cumulative and is the drug count.
[0061] In operation, the canister 130 is vibrated by the drive unit
in order to move countable solid drugs from the canister 130 into a
vial. A controller 180 controls the vibration of the drive unit.
The vibration of the drive unit is controlled to a specific range
of amplitudes, frequencies, or both. Initially the amplitude and
frequency are set to values that are preset based on a drug's and
canister's characteristics and that are stored in a host computer
which is further described below. The drug is counted by the
counting mechanism as it is dispensed. This drug count is compared
to the total count that is to be dispensed according to the patient
order. The amplitude, frequency, or both, of the single drive unit
vibrations are decreased as the drug count nears the total
count.
[0062] The control of the drug fill rate, from the canister 130 to
the vial, is critical to the ability to accurately dispense drugs.
The practice has been to tune the canister inertia, or the spring
rate of the drive mechanism, or both, to resonate close to the
drive frequency ("resonance frequency"). The drive frequency may,
for example, be set equal to the supply line frequency, such as 60
hertz, of the voltage applied to the single drive unit.
[0063] The amplitude of the canister 130 vibration is controlled by
modulating the power supply to the single drive unit. This control
can be accomplished by variation of the voltage with an
auto-transformer or by phase chopping which limits the power
directly by shutting off the power for part of each power cycle
(e.g. 6 milliseconds on for each 8.3 milliseconds per half cycle at
a 60 hertz frequency).
[0064] A variable frequency may be applied to allow the canister
130 to vibrate. This allows for compensation in the frequency due
to a change in the effective inertia of the canister. The effective
inertia of the canister will change due to the amount of drug
present in such a container. As a drug is dispensed, the effective
inertia reduces and the frequency can be adjusted to compensate for
this change. In this way the desired fill rate can be maintained
regardless of the amount of drug present in the canister 130. The
frequency may also be varied to change the dispense rate of the
canister. The method of dispensing solid oral drugs is depicted in
the flow chart of FIG. 5.
[0065] The control of the amplitude and frequency of the vibration
of a canister 130 may include a method and apparatus, such as a
sensor, for monitoring the vibrations. For example, a shutter may
be included on the canister which interposes a light source and
photodetector positioned adjacent to the vibratory dispenser 190.
The light source is blocked intermittently as the canister 130
vibrates and a corresponding intermittent signal is generated by
the photodetector. The signal may be monitored and used to control
the vibration and frequency.
[0066] The control of the amplitude and frequency of the vibration
of a canister 130 may include selection of amplitude, frequency or
both from a table of such values. The controller 180 may be
provided with a list of amplitudes and frequencies that are
tabulated according to drug and are identifiable according to the
drug to be delivered. When a drug is to be dispensed by the
vibratory dispenser 190, the controller 180 sets the amplitude,
frequency, or both the amplitude and frequency of the vibration to
the value contained in the list.
[0067] Fill Rate Control. In order to minimize the fill time, the
drive frequency is increased slowly until it approaches the maximum
detection rate of the sensor. The drug count is a discrete integer
count registered in a fixed sampling time. A moving average is used
as the basis to predict when the last drug will fall through the
sensor. As the drug count approaches the total count, the time to
terminate the fill is predicted as a fraction of the sampling time
of the counting mechanism. The vibration of the canister 130 or
unit-of-use bin 145 by the vibrating dispenser 190 is terminated
when the estimated time to terminate is reached. In the expected
event that the count is short one or two solid drugs, the drive
mechanism is restarted as the last used frequency for a short time
pulse, 25 milliseconds to 100 milliseconds, for example. Then the
drive mechanism is turned off at least until the next drug count
registers. If the count is still short, this process is
repeated.
[0068] Vial Fill Sequence. The robotic assembly 140 brings the vial
under a filling position of the vibratory dispenser 190 and a
signal from the controller system activates the appropriate
canister as required. The doses are counted into the vial until
filling is complete.
[0069] Once a vial is filled, the vial is transported to a capping
machine 155 ("capper") by the robotic assembly 140. The capping
machine 155 preferably applies a child-resistant cap to the
vial.
[0070] As illustrated, each line includes a line scanner 157 and a
wrap belt or drive roller 159. Both the wrap belt and drive roller
serves to spin a vial around so that a code on the vial label can
be read by the line scanner 157. The line scanner 157 verifies the
legibility of the code on the label and confirms the prescription
number to the control system. Preferably, the barcode on the vial
label is read just after the label is applied and before the
canister 130 is retrieved. This sequence of events provides for
verification of the label and that the drug called for on the label
is in stock before the canister 130 is retrieved.
[0071] After the vial is capped, a sensor associated therewith
verifies that the cap has been properly applied. The capper 155
preferably includes a reservoir that is sufficiently large to store
one full shift's supply of caps. The capping machine can be one
similar to Kalish Cap Mark III manufactured by HG Kalish Inc., 6535
Mill Creek #62, Mississauga, Ontario, Canada or Capramatic DLR-1
manufactured by National Instrument Co., 4119 Fordleight Road,
Baltimore, Md.
[0072] Once a vial has been capped and the contents are verified by
the capper sensor, the vial is transported by the robotic assembly
140 to the accumulation receptacle 165 in the accumulation area
163. In the accumulation area 163, two functions can be performed:
sorting and ejecting. Vials that have an improper drug count,
unreadable labels or improperly sealed caps are ejected. A signal
sent by the vibratory dispenser 190, labeler 170, or capper 155
causes a defective vial to be ejected into a reject bin by a blast
of a pneumatic air gun if any of the eject conditions are detected.
When a vial is ejected, the control system places a refill request
with the vibratory dispenser 190 on a priority basis so that
another attempt is made to complete the prescription order.
Alternately, an operator can be alerted to vials that have an
improper drug count, unreadable labels or improperly sealed caps,
by information posted by a host computer that is further described
below.
[0073] Accumulation Receptacles. The accumulation receptacles 165
are bar coded or the accumulation receptacles 165 are identified by
a set of x, y, z coordinates specific to their location in the
machine 105. The control system assigns at least one accumulation
receptacle 165 per patient. If a particular patient has more vials
than a single accumulation receptacle can hold, a second or third
accumulation receptacle will also be assigned. Where used, the bar
code on the accumulation receptacle 165 is read by line scanner
157, and a signal correctly controls the discharge of a specific
patient's vial or unit-of-use drug into the accumulation receptacle
165. Alternately, the discharge of a specific patient's vial or
unit-of-use drug into the accumulation receptacle 165 can be
controlled based on the set of x, y, z coordinates specific to the
accumulation receptacle's 165 location in the machine 105.
Accumulation receptacles 165 may be stationary or they may be
moveable.
[0074] Methods. In FIGS. 5-7, the methods for various aspects of
the system are illustrated. As illustrated in FIG. 5, a host
computer 70 provides a patient's order information to a control
system 80. In return, the control system 80 advises the host
computer 70 as to whether an order is valid or invalid.
[0075] A Patient Entry List 101 is provided, which includes a
collection of patient orders received by the control system 80 from
the host computer 70. Generally, the orders are organized in a
first-in, first-out (FIFO) list. However, when orders receive
priority status, such as during a refill as described above, a
later order can be placed at the head of the list so that it will
be processed first. Also, an order can be removed from the FIFO
list if a drug is not in stock, to optimize machine 105 operation,
and for any special priority reasons. This ability to modify a FIFO
list is characteristic of all FIFO lists or queues used in the
present invention.
[0076] Each entry on the Patient Entry List 101 includes patient
specific information, for identification purposes, one or more
prescriptions for a patient, and prescription specific information
including, for example, an ("NDC") number for each prescription
entered.
[0077] A Receptacle Wait Queue 102 is used to temporarily hold a
patient's order pending availability of one of the accumulation
receptacles 165. This is a FIFO queue and when an accumulation
receptacle 165 becomes available, the order held the longest is
assigned to that accumulation receptacle 165.
[0078] A Restock List 104 is a FIFO list that is used whenever a
canister 130 or unit of use bin 145 does not contain a sufficient
quantity of drug to fill a patient's order. When such is the case,
the unfilled order is removed from the Patient Entry List 101 and
placed at the end of the Restock List 104 until the designated
canister 130 is filled or an operator chooses to dispense less than
the prescribed quantity of drug.
[0079] A Patient Filling List 106 is a FIFO list which is used once
it has been determined that an order can be filled by the system
100. Once such a determination is made, a patient's order is
transferred from the Patient Entry List 101 and placed at the end
of the Patient Filling List 106.
[0080] Prescription Waiting Lists 108 are FIFO lists that are
created when it has been determined that a patient's order can be
filled. When such a determination is made, a prescription in a
patient's order is placed at the tail end of the appropriate
Prescription Wait List 108. Prescriptions are removed from a
Prescription Wait List 108 in the order received.
[0081] Prescription Sort Lists 111 are randomly accessible lists
used once prescriptions have been filled. Once a prescription is
filled, the prescription is placed at the end of the associated
Prescription Sort List 111.
[0082] The Prescription Sort Lists 111 are used by the control
system 80, as discussed below, to place vials into the correct
accumulation receptacle 165. Prescriptions are randomly removed
from these lists as they are placed into the accumulation
receptacles 165.
[0083] As illustrated in FIG. 8, a Prescription Wait Queue 112 is
generally a FIFO list containing listings of prescriptions to be
filled.
[0084] The Prescription Fill Lists 114 are used when vials are to
be filled or unit-of-use drugs are to be dispensed. When an
accumulation receptacle 165 becomes available, as discussed below,
prescriptions are taken off of the associated Prescription Wait
Queue 112 and placed at the tail end of the Patient Filling List
106. At that time, vial is positioned on the filling line for the
prescription to be filled or a unit-of-use drug is picked. After
the prescription is filled and left waiting to enter the
accumulation receptacle 165, it is removed from this list.
[0085] Prescription Restock Lists 116 are FIFO lists used whenever
a prescription cannot be filled from a canister 130 or unit-of-use
bin 145. If it is determined, as discussed below, that a
prescription cannot be filled, the prescription is transferred from
an associated Prescription Wait Queue 112 to this list until the
canister 130 or unit-of-use bin 145 is restocked or an operator
chooses to dispense less than the prescribed quantity of drug.
Then, the prescription is reinserted in a Prescription Wait Queue
112 at the head of the list.
[0086] Prescription Filled Queues 118 are used after vials or
unit-of-use drugs have passed the line scanners. When such is the
case, a prescription is placed at the tail end of the Prescription
Filled Queues 118. Each entry in a Prescription Filled Queue 118 is
flagged to indicate the specific accumulation receptacle to which
the associated vial or unit-of-use drug is to be sent, or if the
vial is to be directed to the reject bin, or if the associated vial
or unit-of-use drug is to be held for an operator to manually
perform an action on the vial or unit-of-use drug. This is a FIFO
queue.
[0087] As illustrated in FIG. 7, a Prescription Sorted List 120 is
used when a vial or unit-of-use drug is about to be dropped into
the assigned accumulation receptacle 165. Prescriptions are
transferred to this list from the Prescription Sort Lists 111, as
described below, when a determination is made to drop a
prescription into an accumulation receptacle 165. Prescriptions are
deleted from this list when the prescriptions are dropped into the
accumulation receptacle 165.
[0088] A Patient Filled List 122 is used after a patient's order
has been filled. When such is the case, a patient's order is
removed from the Patient Filling List 106 and placed at the tail
end of the Patient Filled List 122.
[0089] With the foregoing description, of the various lists and
queues employed in the control system 80, the various processes
employed by the system 100 under the control of the control system
80 will now be described.
[0090] Patient Entry Process. As illustrated in FIG. 8, the patient
data entry process 200 can be described as follows: first, it is
determined by the control system 80 whether the host computer 70 is
linked up thereto. If not, then the control system 80 sits in a
"wait" state. If the host is linked up, then the control system 80
waits for a patient's order information to be provided from the
host computer 70. Once the patient order is received, the control
system 80 determines whether the patient order information is
valid. If the information is not valid, then an error message is
sent to the host computer to inform the operator of the error. If
the patient order information is valid, then the patient's order,
compromising one or more prescriptions and patient specific data,
is placed on the Patient Entry List 101 as described above and
illustrated in FIG. 8. Subsequently, an acknowledgment is sent to
the host computer 70 to inform the operator thereof that the
patient order was placed on the Patient Entry List.
[0091] Canister Location Optimization Process. The canister 130
location within the system 100 is based on the use of the drug
stored within the canister 130. Canisters 130 that are more
frequently accessed during the dispensing of countable oral solid
drugs are stored closer to the location of the vibratory dispenser
190. In this way, time to fill prescriptions is reduced not only
for the frequently dispensed drugs, but is cumulatively reduced for
all prescriptions filled. In this process, the number of times each
canister 130 is accessed is compared for a given time frame. Such a
time frame of comparison may be a day, week, month, or longer. The
canisters 130 are then listed in an order based on the number of
times each canister 130 was accessed during the time frame from
most number of times to the least number of times. The canisters
130 are then placed into storage locations, by the robotic assembly
140, in the order determined above.
[0092] Patient Fill Process. The patient fill process is the
process by which a patient's order is divided into the various
prescriptions which are then assigned to be filled. As illustrated
in FIG. 9, in this process, the system waits for a patient's order
to be placed in the Patient Entry List 101. For every patient order
in the Patient Entry List 101, a prescription filling assignment is
provided so that the fill process is accomplished in an optimal
manner. However, the prescriptions are not filled at this time.
[0093] Subsequently, it is determined whether the prescriptions are
successfully assigned to be filled. If not, the patient order is
placed on the Refill List 104 and the prescriptions are removed
from the Prescription Filling Lists 114. If the prescriptions are
successfully assigned, it is determined whether an accumulation
receptacle 165 is available for receipt of the patient order. If an
accumulation receptacle 165 is not available, then the patient
order is placed in the Bin Wait Queue 120 and the prescriptions are
removed from the Prescription Fill Lists 114. The process 202 then
again waits for a patient's order information to be presented in
the Patient Entry List 101.
[0094] If an accumulation receptacle 165 is available, then the
patient's order is placed on the Patient Filling List 106 and an
accumulation receptacle 165 is selected and assigned to this
patient, as discussed below. Subsequently, the process for filling
prescriptions commences.
[0095] Filling Line Assignment. The process used to determine the
filling line assignment for a prescription, is illustrated in FIG.
10. It is determined whether the filling of this particular
prescription will deplete the drug quantity of the associated
canister 130 or unit-of-use bin 145 below a minimum. If the answer
is yes, then a restock request is generated to indicate to the
system operator or pharmacist to restock the canister 130 or
unit-of-use bin 145. Then it is determined whether the prescription
will fully deplete the associated canister 130 or unit-of-use bin
145. If the answer is yes, then the process is terminated and
non-assignment is indicated.
[0096] If it is determined that the filling of the prescription
will not run the drug quantity below a minimum or that filling the
prescription will not run a canister 130 or unit-of-use bin 145
empty, then the prescription is assigned to the associated
Prescription Wait List 108 with a dormant flag set to true. At
start up, all accumulation receptacles 165 are empty. An
accumulation receptacle is recognized as being the first unassigned
accumulation receptacle available 165 (see FIG. 9), as it keeps
track of all accumulation receptacle numbers and assigns
accumulation receptacles 165 to patient orders.
[0097] Receptacle Accumulation Process. A Receptacle Accumulation
Process 204 determines if any patient's orders are in the
Receptacle Wait Queue 102 and, if so, places such orders at the
head of the Patient Entry List so that they are processed next.
[0098] As illustrated in FIGS. 11 and 12, at the beginning of this
process it is determined whether an accumulation receptacle 165 is
available. A determination is made as to whether any patient orders
are in the Receptacle Wait Queue and whether the particular
accumulation receptacle 165 is available. If the determination is
negative, then the entire process is repeated. Otherwise, the
patient's order information is removed from the Receptacle Wait
Queue 102 and placed at the head of the Patient Entry List 101.
Then the entire process recommences.
[0099] Restock Process. A Restock Process 206 is invoked if any
canister 130 or unit-of-use bin 145 should not have a quantity
sufficient to fill any prescription within a patient's order. As
illustrated in FIG. 13, the Patient Fill Process 202 takes the
order off the Patient Entry List 101, as described above and
transfers it to the Restock List 116 until the canister 130 or
unit-of-use bin 145 required has been restocked. Alternately, as
described above, an operator may intervene and chose to dispense
less than the prescribed quantity of drug.
[0100] In the Restock Process 206, a continuous routine waits in a
loop for indicators that a canister 130 or unit-of-use bin 145 has
been restocked. When a determination is made as to whether any
patient orders in the Prescription Restock List 116 are waiting for
the indicated restock. If no orders are waiting for the indicated
restock, the routine recommences. Any patient order placed in the
Prescription Restock List 116 waiting for this restock is removed
and placed at the head of the Patient Entry List 101. Otherwise, it
is determined whether any prescriptions on a Prescription Restock
List 116 are waiting for the indicated restock. If the answer is
negative, then the restock routine returns to the beginning. If the
answer is affirmative, the prescriptions are removed from the
Prescription Restock List 116 and placed at the associated head of
the Prescription Wait Queue 112. Then, the restock routine returns
to the beginning to wait for a further indication of a restock.
[0101] Fill Process. A Prescription Fill Process 208 is actually a
collection of processes, lists, and hardware interfaces as
illustrated in FIG. 9. As illustrated in FIG. 14, in this process
208, a routine commences with a wait or sleep state of about 500
milliseconds. Subsequently, a determination is made as to whether
an associated Prescription Fill List 114 is empty. If the
Prescription Fill List 114 is not empty, then a check is made of
the Filling Line Function, as described below.
[0102] After the Filling Line Function is checked or if the
associated Prescription Fill List 114 is empty, then a
determination is made as to whether the associated Prescription
Wait Queue 112 is empty. If the Prescription Wait Queue 112 is
empty, then the routine returns to the beginning. Otherwise, a
determination is made as to whether the Prescription Wait Queue 112
entry dormant flag is set to true. If the Prescription Wait Queue
112 entry dormant flag is set to true, then the routine
recommences. Otherwise, a determination is made as to whether the
filling of the prescription would empty the requisite canister 130
or unit-of-use bin 145. If the filling of the prescription would
empty the requisite canister 130 or unit-of-use bin 145, then the
prescription is placed on the associated Prescription Restock List
116 and a restock request is generated. Then the routine
recommences.
[0103] If filling of the prescription would not empty the requisite
canister 130 or unit-of-use bin 145, then a check for an assignment
of a free accumulation receptacle 165 is made. If a free
accumulation receptacle 165 is not available for assignment, then
the routine is recommenced. Otherwise, if a free accumulation
receptacle 165 is assignable, then the prescription is removed from
the Prescription Wait Queue 112 and moved to the Prescription Fill
List 114. At the same time, a command is issued to the associated
unscrambler 110 to prepare a vial.
[0104] Check Filling Line Function. As illustrated in FIG. 15, the
check of a filling line made during a Prescription Fill Process 208
commences with a check of the associated unscrambler 110 and
continues with a check of the associated vibratory dispenser 190,
labeler 170, capper 155, and line scanner 157.
[0105] Unscrambler Check. As illustrated in FIG. 16, when the
unscrambler 110 is checked, a determination is made as to whether a
vial preparation command is pending. If no vial preparation command
is pending, then the check is discontinued. If a vial preparation
command is pending, then a determination is made as to whether the
unscrambler 110 is ready to respond. If the unscrambler 110 is not
ready to respond, then the check is terminated. If the unscrambler
110 is ready to respond, then a determination is made as to whether
a vial has been successfully prepared. If a vial has been
successfully prepared, then a command is issued to the unscrambler
110 to prepare a vial and the unscrambler check is terminated.
[0106] Labeler Check. As illustrated in FIG. 17, when the labeler
170 is checked, a routine is executed that, as a first step,
determines whether a labeler command is pending. If no labeler
command is pending, then the routine is terminated. If a labeler
command is pending, then a determination is made as to whether a
labeler response is ready.
[0107] If no labeler response is ready, then the routine is
terminated. If a labeler response is ready, then a determination is
made as to whether any errors have occurred in the unscrambler
process. If no errors have occurred, then the prescription is
assigned a status of "waiting for filling" and a command is issued
to the fill the vial. Then the routine is terminated. If an error
in the unscrambler process is detected, then an error handling
routine is invoked and the labeler checking routine is
terminated.
[0108] Vibratory Dispenser Check. As illustrated in FIG. 18, if a
vial has been successfully prepared, then the prescription is
assigned a status of "waiting for vibratory dispenser" and a check
is then made of the vibratory dispenser 190.
[0109] The check of the vibratory dispenser 190 commences with a
determination as to whether a vibratory dispenser command is
pending. If a vibratory dispenser command is not pending, then a
determination is made as to whether a prescription is assigned the
status "waiting for filling." If no prescription is assigned the
status "waiting for filling," then the check of the filling is
terminated. If a prescription is assigned the status "waiting for
filling," then a command is issued to the vibratory dispenser to
fill the prescription. Then the check of the vibratory dispenser is
terminated.
[0110] If at the beginning of the check of the vibratory dispenser
190, it is determined that a vibratory dispenser command is
pending, then a determination is made as to whether a vibratory
dispenser response is ready. If a vibratory dispenser response is
not ready, then the check of the vibratory dispenser 190 is
terminated. If a vibratory dispenser response is ready, then a
determination is made as to whether a prescription has been already
filled. If a prescription has not been successfully filled then a
signal is issued to alert the system operator or pharmacist of the
partially filled vial and the vial is handled appropriately. Then
the check of the vibratory dispenser 190 is terminated. If it is
determined that a prescription has been successfully filled, then
the check of the vibratory dispenser 190 is also terminated.
[0111] Capper Check. As illustrated in FIG. 19, when the capper 155
is checked, a routine is invoked that, as a first step, determines
whether a command is pending directing the associated capper 155 to
cap a vial, referred to as a capper command.
[0112] If no capper command is pending, then the routine is
terminated. If a capper command is pending, then a determination is
made as to whether a capper response is ready. If a capper response
is not ready, then the routine is terminated. If a capper response
is ready, then a determination is made as to whether any errors
have been detected in the filling process. If no errors have been
detected, then the prescription status is assigned a status of
"waiting for line scanner." If errors are detected, then the error
handling routine is invoked and the capper check routine is
terminated.
[0113] Line Scanner Check. As illustrated in FIG. 20, when the line
scanner 157 is checked, a routine is invoked that determines
whether a line scanner message is present. If no line scanner
message is present, then the routine is terminated. If a line
scanner message is present, then a determination is made as to
whether there is a match between the prescription information on
the label and the appropriate prescription information in the
Prescription Fill List 114. If the label and the Prescription Fill
List 114 information match, then the prescription is transferred to
the Prescription Filled Queue 118 with an accumulation receptacle
165 number. Subsequently, the prescription is assigned a status of
"pending delivery" and the line scanner routine check is
terminated. If an error is detected, or if there is no match
between the label and the Prescription Fill List 114 information,
the prescription is transferred to a Prescription Filled Queue 118
with a reject flag. Then the check line scanner routine is
terminated. The line scanner 157 may be checked after a label is
applied to a vial and before a drug is dispensed.
[0114] Accumulation Receptacle Check. As illustrated in FIG. 21,
the accumulator area 163 is checked to determine whether a free
accumulation receptacle 165 exists. If an accumulation receptacle
is free, it is assigned. If no accumulation receptacles are free,
then the routine is terminated.
[0115] Staging Input Process. As illustrated in FIG. 22, the
Staging Input Process 210 removes prescriptions from the
Prescription Filled Queue 118 in a FIFO order. This process also
determines if the prescription flagged is "good," i.e., not
rejected. If the prescription is flagged as good, then the
prescription is placed into an assigned accumulation bin by the
robotic assembly. The prescription is then removed from the
Prescription Filled Queue 118 and placed at the tail end of the
Prescription Sort List 111.
[0116] If the prescription is flagged as bad, a command removes the
prescription order from the Prescription Filled Queue 118. The vial
is ejected into the reject bin by a blast of air prior to reaching
the accumulator area 163 and any assigned accumulator area 163 is
freed up. Alternately, as described above, a vial may be held up
until an operator chooses to dispense less than the prescribed
quantity of drug or to reject the vial.
[0117] To accomplish the foregoing, as a first step, this process
determines whether there is an entry in the Prescription Filled
Queue 118. If no entry is made, then this routine loops until an
entry is made in the Prescription Filled Queue 119. Subsequently,
the prescription information is transferred from the Prescription
Filled Queue 118 to the Prescription Sort List 111 and the staging
input process routine recommences.
[0118] Prescription Sort Process. As illustrated in FIG. 23, in the
Prescription Sort Process 212, prescriptions are matched with the
accumulation receptacles 165. As described above, accumulation
receptacles may be moveable or stationary. An accumulation
receptacle 165 is checked for assignment to a patient. If it is
assigned to a patient, the patient's information is found in the
Patient Filling List 106. This list entry is then used to check if
any of the prescriptions in the Prescription Sort List 111 (i.e.,
those vials or unit-of-use drugs) need to be dropped into this
accumulation receptacle. If a prescription needs to be dropped into
this accumulation receptacle, it is removed from the Prescription
Sort List 111 and placed at the tail end of the associated
Prescription Sorted List 120. The patient order is then checked for
completion (i.e., all prescriptions dropped into the patient's
accumulation receptacle). If the patient's order is complete the
patient's order is removed from the Patient Filling List 106 and
placed at the tail end of the Patient Filled List 122.
[0119] In a routine for this process, as a first step, a
determination is made as to whether a line scanner message exists.
If no message exists, then the routine loops back to the beginning.
If a line scanner message exists, then a determination is made as
to whether an accumulation receptacle is assigned. If an
accumulation receptacle 165 is not assigned, then the routine
recommences. If an accumulation receptacle 165 is assigned to a
patient, then a determination is made as to whether any
prescriptions are to be placed in the assigned accumulation
receptacle 165. If no prescriptions are to be placed in this
accumulation receptacle 165, then the prescription routine
recommences. If prescriptions are to be placed in the accumulation
receptacle 165, then a command is issued to start the Staging
Output Process 214. Subsequently, the prescription is removed from
the Prescription Sort List 111 and the patient's prescription
status is updated on the Patient Filling List 106. Then a
determination is made as to whether a patient's order is complete.
If a patient's order is not complete, the routine is recommenced.
If the patient's order is complete, then the patient's order is
transferred from the Patient Filling List 122 to a Patient Filled
List.
[0120] It should be understood that various changes and
modifications to the presently preferred embodiments described
herein will be apparent to those skilled in the art. Such changes
and modifications can be made without departing from the spirit and
scope of the present invention and without diminishing the
attendant advantages of the invention. It is therefore intended
that such changes and modifications be covered by the appended
claims.
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