U.S. patent application number 09/871532 was filed with the patent office on 2002-12-05 for systems for feeding, counting and dispensing discrete objects.
This patent application is currently assigned to Kirby-Lester, Inc.. Invention is credited to Geltser, Aleksandr, Gershman, Vladimir.
Application Number | 20020179619 09/871532 |
Document ID | / |
Family ID | 25357659 |
Filed Date | 2002-12-05 |
United States Patent
Application |
20020179619 |
Kind Code |
A1 |
Geltser, Aleksandr ; et
al. |
December 5, 2002 |
SYSTEMS FOR FEEDING, COUNTING AND DISPENSING DISCRETE OBJECTS
Abstract
A discrete object counting and dispensing system includes an
object counter, a funnel couplable relative to the object counting
system such that when discrete objects are provided in the funnel,
the discrete objects are counted by the object counting system. The
system also includes a vibration system which vibrates in a
substantially horizontally circular plane in a rotational
direction, a mounting assembly rigidly coupled to the vibration
system, and a discrete object container couplable to the mounting
assembly. The container has a reservoir and an exit, and is adapted
to feed discrete objects from the reservoir to the exit when the
container is vibrated by the vibration system. When the discrete
objects are exited from the exit, the discrete objects are counted
by the object counting system and then dispensed.
Inventors: |
Geltser, Aleksandr;
(Stamford, CT) ; Gershman, Vladimir; (Stamford,
CT) |
Correspondence
Address: |
David P. Gordon, Esq.
65 Woods End Road
Stamford
CT
06905
US
|
Assignee: |
Kirby-Lester, Inc.
|
Family ID: |
25357659 |
Appl. No.: |
09/871532 |
Filed: |
May 31, 2001 |
Current U.S.
Class: |
221/2 |
Current CPC
Class: |
B65G 47/145 20130101;
G07F 11/44 20130101; A61J 7/02 20130101; G07F 17/0092 20130101;
B65B 37/04 20130101; G07F 13/025 20130101; B65B 57/20 20130101 |
Class at
Publication: |
221/2 |
International
Class: |
G07F 011/00 |
Claims
1. A system for feeding and counting discrete objects, comprising:
a) an object counting system; b) a funnel couplable relative to
said object counting system such that when the discrete objects are
provided in said funnel, the discrete objects are counted by said
object counting system; c) a vibration system which vibrates in a
substantially horizontally plane in a rotational direction; d) a
mounting assembly rigidly coupled to said vibration system; and e)
a discrete object container having a reservoir and an exit, said
container couplable to said mounting assembly and relative to said
object counting system such that the discrete objects are fed from
said reservoir to said exit when said container is vibrated by said
vibration system, and such that the discrete objects exiting said
exit are counted by said object counting system.
2. A system according to claim 1, wherein: only one of said funnel
and said discrete object container are couplable at a time relative
to said object counting system in a manner which permits counting
of the discrete objects.
3. A system according to claim 1, wherein: said object counting
system includes at least one optical sensor array.
4. A system according to claim 3, wherein: said at least one
optical sensor array includes an orthogonal arrangement of optical
sensors.
5. A system according to claim 3, wherein: said object counting
system includes two optical sensors.
6. A system according to claim 3, wherein: said optical sensors are
adapted to sense multiple objects simultaneously falling pass said
sensors.
7. A system according to claim 1, further comprising: f) a housing
having a chute, said object counting system including sensing means
provided along said chute for sensing the discrete objects, wherein
said funnel is couplable at or adjacent a top of said chute.
8. A system according to claim 7, further comprising: g) a shield
adapted to at least partially shield an entrance to said chute.
9. A system according to claim 8, wherein: said shield is couplable
relative to said object counting system and only one of said funnel
and said shield is couplable at a time relative to said object
counting system.
10. A system according to claim 1, wherein: said system for feeding
and counting is adapted to function as a pour-through counter when
discrete objects are provided into said funnel, and as a preset
counter when said container is provided on said mounting
assembly.
11. A system according to claim 10, further comprising: f) a sensor
which senses whether said container is provided on said mounting
assembly, said sensor adapted to provide a signal which determines
whether said system functions as a pour-through counter or a preset
counter.
12. A system according to claim 1, further including: f) a keypad
by which a desired number of the objects to be counted can be
entered; and g) a display which displays the number of the objects
counted.
13. A system according to claim 1, wherein: said container is a
cassette having an enclosed reservoir, and a partially covered tray
area including said exit, wherein when said cassette is provided on
said mounting assembly and vibrated by said vibration system, the
discrete objects move from said reservoir to said tray area and
exit through said exit.
14. A system according to claim 13, wherein: said cassette includes
a plurality of exits, each of which directs the discrete objects to
be counted by said object counting system.
15. A system according to claim 1, wherein: said mounting assembly
includes an electromagnet, and said container includes a metal
element which is coupled to said electromagnet when said
electromagnet is activated.
16. A system according to claim 15, wherein: said electromagnet has
a cross-sectional shape, and a bottom portion of each said cassette
includes a recess substantially having said cross-sectional
shape.
17. A system according to claim 1, wherein: said container is an
open hopper including said reservoir, a ramp, and said exit,
wherein when said hopper is provided on said mounting assembly and
vibrated by said vibration system, discrete objects move from said
reservoir along said ramp, and exit through said exit.
18. A system for feeding and counting discrete objects, comprising:
a) a housing including a chute; b) an object counting system which
counts discrete objects passing through said chute; c) a funnel
removably coupled in said housing in communication with said chute;
d) a mounting assembly exposed at a top of said housing, said
mounting assembly adapted to receive a container holding discrete
objects; and e) a movement system adapted to move a container
coupled to said mounting assembly.
19. A system according to claim 18, further comprising: f) a
container couplable to said mounting assembly, said container
including a reservoir adapted to hold the discrete objects, and an
exit at which the discrete objects exit into said chute.
20. A system according to claim 19, wherein: said mounting assembly
includes an electromagnet and said container includes a metal
portion which is coupled relative to said electromagnet when said
electromagnet is activated.
21. A system according to claim 19, wherein: said container is a
cassette having an enclosed reservoir.
22. A system according to claim 21, wherein: said container
includes an alignment element which aligns said exit with said
chute.
23. A system according to claim 18, further comprising: f) means
for configuring said object counting system for passthrough
counting or preset counting.
24. A system according to claim 23, wherein: said means for
configuring is automatically set to preset counting when the
container is provided on said mounting system.
25. A system according to claim 18, further comprising: f) a spout
in vertical alignment with said chute, said spout having a
gate.
26. A system according to claim 18, further comprising: f) a spout
mount coupled relative to said housing; and g) a spout removably
couplable to said spout mount in vertical alignment with said
chute.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates broadly to feeding, counting and
dispensing apparatus. More particularly, this invention relates to
combined-type systems which feed, count, and dispense discrete
items, such as tablets, capsules or caplets.
[0003] 2. State of the Art
[0004] In retail, hospital, and mail order medication dispensing, a
large number of different prescriptions of single dose medications,
such as tablets, must be filled. (Hereinafter, for purposes of
brevity, reference to "tablets" should be understood for purposes
herein as being generic to tablets, capsules, caplets and any other
solid dose medication). For prescriptions requiring small
quantities of a medication, the prescription is often filled by
hand; that is, a bulk container containing the prescription
medication is removed from a shelf and opened. A quantity of the
medication is poured into a tray and the medication tablets are
counted by a pharmacist and then dispensed into a patient
prescription bottle. The remainder of the medication in the tray is
returned to the bulk container, the container is closed, and then
replaced on the shelf.
[0005] Larger quantity prescriptions are often filled with the aid
of a counting apparatus intended to more rapidly count different
quantities of different tablets successively. For example, a
prescription for ninety tablets of 10 mg Claritin.RTM. may need to
be filled after a prescription for sixty tablets of 400 mg
Motrin.RTM.. Generally, there are two types of counting apparatus
available for dispensing prescription medication from bulk
containers of such medications: a preset counter and a pour-through
counter.
[0006] With a preset counter, the pharmacist obtains a bulk
container of a prescription medication from a shelf and then pours
from the container a quantity of tablets into a hopper of the
counting apparatus. The pharmacist then sets the counting apparatus
to the number of tablets to be counted, e.g., ninety. Assuming at
least the required number of tablets for the prescription has been
poured into the hopper, the pharmacist waits while the counting
apparatus counts the required number of tablets and dispenses the
tablets into a patient prescription bottle. The excess tablets are
discharged back into the bulk container, which is then replaced on
the shelf. It has been found that the time taken to discharge the
excess tablets can be equal to or greater than the time required to
count the prescription. For that reason, the pour-through counter
has proved more popular.
[0007] A pour-through counter does not include a hopper that
temporarily stores the medication. Rather, the pharmacist pours
tablets from a bulk container directly into a funnel which drops
the tablets past a counter and dispenses them into a patient
bottle. The pharmacist pours until the digital readout of the
counter apparatus displays the required number of tablets, and then
stops. As such, there is usually no excess. However, should an
extra tablet or so fall into the funnel, the readout clearly
indicates the extra number, and the excess can easily be removed by
the pharmacist and returned to the storage container.
[0008] Both the preset and pour-through counter systems have a
common drawback. Each prescription medication must be obtained from
a bulk storage container located in stock, which must be opened
prior to use and closed after use. In order to minimize the time
taken to dispense a prescription, counter manufacturers have
provided "cassette counters" for retail, hospital, and mail order
pharmacies. Each cassette is designed for a specific size and shape
capsule, tablet, or caplet. The cassettes are pre-filled by the
pharmacist with bulk quantities of the appropriate prescription
drugs, and are used to store bulk quantities rather than using the
container supplied by the manufacturer. The prescription medication
is then dispensed directly from the cassette. The use of cassettes
eliminates the time needed to open the manufacturer's original
container, the time needed to return excess tablets to the
container, and the time needed to close the container.
Unfortunately, cassette counters are slow and prone to breaking
tablets. Furthermore, when cassettes jam, as they often do, they
are difficult to unclog. Often tablets spill uncontrollably from
the cassette during attempts to unclog a jam. Further, since the
cassettes used in existing cassette systems are specific to the
tablet being dispensed, each time a pharmacist wants to count a new
drug, a new cassette designed for that specific medication must be
obtained. In addition, some prescriptions are filled infrequently
and it is not economically feasible or practical to have a
dedicated cassette for every solid dose medication in the
pharmacy.
SUMMARY OF THE INVENTION
[0009] It is therefore an object of the invention to provide a
system for counting and dispensing discrete objects such as
tablets, capsules and the like which permits storing discrete
objects in a manner in which the objects may be quickly
dispensed.
[0010] It is another object of the invention to provide a counting
and dispensing system which uses cassettes which are not customized
to a particular tablet or capsule.
[0011] It is a further object of the invention to provide a
counting and dispensing system which uses cassettes which are
relatively inexpensive to manufacture.
[0012] It is an additional object of the invention to provide a
counting and dispensing system which is not subject to jamming by
discrete objects being counted.
[0013] Another object of the invention is to provide a counting and
dispensing system which provides rapid counting of the discrete
objects.
[0014] A further object of the invention is to provide a counting
and dispensing system which can also be used without a
cassette.
[0015] An additional object of the invention to provide a counting
and dispensing system which has the benefits of two different modes
of operation, as a pour through counter, as well as a preset
counter.
[0016] Yet a further object of the invention is to provide a
counting and dispensing system which can also be used with a bowl
feeder.
[0017] Yet another object of the invention is to provide a counting
and dispensing system which is adapted for rapid exchange of
cassettes and bowl feeders.
[0018] It is yet an additional object of the invention to provide a
counting and dispensing system which functions with high
reliability.
[0019] In accord with these objects, which will be discussed in
detail below, an object counting and dispensing system is provided
which includes a vibration system which substantially circularly
vibrates in a horizontal circular plane, a mounting assembly for
coupling a cassette to the vibration system, a chute configured to
receive discrete objects from either the cassette or a funnel and
dispense the objects to a patient bottle, and an object sensing
system which senses and counts objects fed into the chute.
[0020] Each cassette includes a base and a stepped side wall which
together define a central open reservoir portion and at least one
substantially planar covered tray portion surrounding the reservoir
portion. A lid is removably coupled over the reservoir portion. The
reservoir portion is adapted to store tablets and feed the tablets
through a path into the tray portion. The tray portion has a
peripheral exit and guides the fed tablets toward the exit when the
cassette is vibrated by the vibration system. The tray portion
optionally includes a peripheral track which facilitates the
guidance of tablets having non-flat surfaces toward the exit. A
leaf spring gate closes the exit and is automatically opened by a
permanent magnet attached to the tip of a solenoid when the
cassette is attached to the mounting assembly, and closed when the
cassette is removed therefrom. When the last tablet in a batch has
been counted, the magnet is retracted and the leaf spring closes
the exit of the cassette. The leaf spring also closes the cassette
when the cassette is removed from the mounting assembly and moved
away from the magnet. Each cassette includes a lower metal portion
at which the cassette is mounted to the mounting assembly.
Cassettes are mounted to the mounting assembly in a manner which
permits rapid and secure coupling and decoupling. Preferred
coupling means include an electromagnetic coupling system.
[0021] Each cassette is able to feed and guide a range of sizes and
shapes of tablets toward the exit. As such, only a few standard
sizes of cassettes are needed to accommodate a wide range of
discrete objects for which the counter is primarily adapted:
tablets, capsules, caplets, etc. When used with the cassette, the
system functions as a preset counter wherein the counter is preset
to count a desired number of tablets, and the counter then feeds
and counts the exact number of tablets from the cassette.
[0022] As briefly discussed above, according to another aspect of
the invention, the system can be used without the cassette and
operate as a pour-through counter in which tablets are poured into
the funnel.
[0023] In addition, a universal bowl feeder can be attached to the
mounting assembly, preferably in the same manner as the cassettes.
The bowl feeder can accommodate prescriptions which are not
provided with their own cassette and for which it is desired to
preset the number of tablets to be counted.
[0024] Additional objects and advantages of the invention will
become apparent to the skilled in the art upon reference to the
detailed description taken in conjunction with the provided
figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of a system for feeding,
counting, and dispensing discrete objects according to the
invention, shown with a cassette attached thereto;
[0026] FIG. 2 is a plan view of the system for feeding, counting,
and dispensing objects according to the invention, shown with a
cassette attached thereto;
[0027] FIG. 3 is a section view across line 3-3 in FIG. 2;
[0028] FIG. 4 is a section view across line 4-4 in FIG. 2;
[0029] FIG. 5 is a perspective view of the assembly of a vibration
system, a mounting assembly, a chute and a spout, and an object
sensing system, and a cassette attached to the mounting assembly,
the cassette having a gate in an open position;
[0030] FIG. 6 is an exploded perspective view showing the spout
removed from the housing of the system according to the
invention;
[0031] FIG. 7 is a perspective view of a cassette according to the
invention with a lid enclosing the reservoir of the cassette;
[0032] FIG. 8 is a section view across line 8-8 in FIG. 7;
[0033] FIG. 9 is a perspective view of a cassette according to the
invention without a lid enclosing the reservoir of the
cassette;
[0034] FIG. 10 is a plan view of a base portion of the cassette
according to the invention;
[0035] FIG. 11 is a perspective view of the assembly of a vibration
system, a mounting assembly, a chute and a spout, and an object
sensing system, and a cassette attached to the mounting assembly,
the cassette having a gate in an open position;
[0036] FIG. 12 is a bottom perspective view of the mounting system
and the vibration system, the mounting system shown with a cassette
coupled thereto;
[0037] FIG. 13 is a top perspective view of the mounting system and
the vibration system;
[0038] FIG. 14 is a plan view of the base portion of the cassette
provided with capsules and illustrating the movement of capsules
thereon;
[0039] FIG. 15 is a section view of a multi-tray cassette according
to the invention;
[0040] FIG. 16 is a plan view of a bottom tray of the multi-tray
cassette of FIG. 15;
[0041] FIG. 17 is a plan view of a top tray of the multi-tray
cassette of FIG. 15;
[0042] FIG. 18 is an exploded perspective view of the system for
feeding, counting, and dispensing discrete objects according to the
invention, shown with a funnel adapted to be provided in alignment
with the chute of the system;
[0043] FIG. 19 is a plan view of the system for feeding, counting,
and dispensing objects according to the invention, shown with a
funnel attached in alignment with the chute; and
[0044] FIG. 20 is a perspective view of a universal vibratory bowl
feeder attached to the mounting and vibratory assemblies according
to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] Turning now to FIGS. 1 through 5, according to a preferred
embodiment of the invention, an object counting, feeding, and
dispensing system 10 includes a vibration system 12 which
substantially circularly vibrates in a horizontal plane, a mounting
assembly 14, described in detail below, which secures a cassette 16
to the vibration system in a manner in which the cassette may be
rapidly removed such that another cassette can be rapidly secured
to the mounting assembly, a chute 18 oriented to receive discrete
objects from a cassette 16 and feed the objects to a bottle or
container located at an exit spout 21 beneath the chute, and an
object counting system 22 which through windows 23a, 23b senses and
counts objects passing within the chute 18. Hereinafter, the term
`tablets` is used interchangeably with `objects`, unless the
context dictates otherwise.
[0046] The vibration system 12, mounting assembly 14, chute 18, and
object counting system 22 are provided in a housing 24. The housing
24 is provided with a user display 26, and an input panel 28, as
well as a microprocessor 30. The display 26 indicates the number of
tablets counted, and is coupled via the microprocessor 30 to the
object counting system 22. The input panel 28 permits the user to
input a number of tablets which the system is to feed, count and
dispense to a bottle. A power supply 34 is electrically coupled to
the vibration system 12, the mounting assembly 14, the object
counting system 22, the display 26 and input panel 28, and the
microprocessor 30. The object counting system 22 is preferably an
optical system which uses an optical sensor array, such as that
disclosed in co-owned U.S. Pat. No. 5,768,327, which is hereby
incorporated by reference herein in its entirety. The optical
sensor array of U.S. Pat. No. 5,768,327 includes an orthogonal
arrangement of two discrete optical sensors which together sense
objects in three dimensions. This sensor arrangement is adapted to
sense multiple objects simultaneously falling passed the sensors.
Alternatively, the counting system may include any other counter
for counting discrete objects which is known in the art. As shown
in FIG. 6, the spout 21 includes an upper lip 21a at which the
spout is preferably removably mounted on two slides 110, 112 which
holds the spout beneath the chute, but permits removal. The spout
is also preferably provided with a gate 114 which prevents
dispensing from the spout until lifted, thereby preventing the
tablets from spilling from the spout until the user is prepared
with a bottle at the exit spout. The spout 21 may be slidably
removed from the slides 110, 112 for cleaning. In addition, the
spout can be removed for transfer of the contents of the spout to
another location (with the gate in the closed position), and then
inverted to pour the spout contents from the lip end of the
spout.
[0047] Referring to FIGS. 1 and 2, the top of the housing 24
preferably includes an upper deck 120, a lower deck 122, and a
generally vertical wall 124 at the junction thereof. The upper deck
120 includes a circular-portion recess 128 which extends through
the wall 124 and which is sized and shaped to receive a preferably
substantial portion of a cassette 16. The recess 128 is preferably
approximately 2700 in curvature. The mounting assembly 14 is
accessible at the recess 128. The recess 128 also includes a sensor
129 (FIGS. 18 and 19) which senses when a cassette is positioned in
the recess. The chute 18 has an entrance 130 on the lower deck 122
which is preferably provided with a shield 132 which partially
covers the entrance of the chute. The shield 132 has several
functions: it functions as a light shield to prevent stray light
from interfering with the optical sensory array of the object
counting system 22, it functions as a object shield to prevent
stray objects from falling into the chute and being counted, and it
may function as a placement guide to facilitate the rapid placement
of a cassette on the mounting assembly 14. While the shield 132 is
preferably a discrete element which may be positioned in the chute,
it may alternatively be formed as part of the cassette to provide
some or all the same functionality. As such, when the cassette is
provided on the mounting assembly, the shield initially would
function as a guide to facilitate the placement of a cassette on
the mounting assembly, and then shield stray light from the optical
sensory array and prevent stray objects from falling into the
chute.
[0048] Turning now to FIGS. 7 through 10, each cassette 16 includes
a relatively thin preferably plastic base 40 and a preferably
plastic top element comprised of a wall 42 and an annular shelf 43
fixedly coupled to the base such that the base and top element
together define a central reservoir portion 44 and a peripheral
covered tray portion 46. The base 40 preferably includes a
peripheral wall 48, and a reservoir wall 50 concentric with the
peripheral wall and having an opening 52. An entry guide 56 is
obliquely angled relative to the reservoir wall 50 at the opening
52 and defines a narrow 53 between the end of the entry guide and
the peripheral wall which serves as an entry to track area 54. The
base 40 also includes an exit hole 58 adjacent the peripheral wall
48 substantially 2700 counterclockwise relative to the entry guide
56, and an exit guide 60 located relative to the peripheral wall 48
such that tablets traveling between the peripheral wall 48 and the
exit guide 60 are directed in a single file to the exit hole 58.
The base 40 preferably includes a return guide 62 which facilitates
movement of tablets which have not entered the exit guide 60 in the
counterclockwise direction back toward the entry guide.
[0049] In the preferred embodiment, the opening 52 is defined
between the entry guide 56 and a free end 64 of the return guide
62. Optionally, a shallow concavely curved or sloped channel 66
having a width for guiding a single tablet or capsule is formed in
the base 40 adjacent a portion of the peripheral wall 48 from the
location of the entry guide 60 counterclockwise to the exit hole
58. The width of channel is preferably between 0.5-1.5 times the
width of the range of tablets or capsules for which the cassette is
designed. The base 40 preferably also includes a central circular
hole 68, and a metal plate 70 on the base over the hole 68 (FIGS. 8
and 9). The plate 70 includes a hole 71, and a post 72 is coupled
in the hole 71 and extends vertically upwards therefrom. The upper
end 74 of the post is threaded. A lid 76 including a central hole
78 is provided on the top element 42 such that the upper end 74 of
the post extends through the hole 78. A knob 80 is threaded onto
the post in order to secure the lid 76 on the top element 42 and to
enclose the reservoir 44 (FIGS. 7 and 8).
[0050] Preferably the height of each of the peripheral wall 48, the
reservoir wall 50, and the guides 56, 60 and 62 is the same, height
H (FIG. 8). The shelf 43 rests on the walls 48 and 50 and guides
56, 60 and 62 to substantially enclose the tray portion 46 to
provide the tray portion with a height H. The height H is
preferably substantially 1.2 to 1.8 times the height of a tablet
(across the diameter of cylindrical capsules and caplets, or
transverse to the flattest surface of a tablet) which is to be
stored in and fed from the cassette. In addition, the opening 52 is
preferably approximately three to eight tablets in size (across the
diameter of cylindrical capsules and caplets or the flattest
surface of a tablet). Furthermore, the narrows 53 is preferably
approximately two to four tablets in size (across the diameter of
cylindrical capsules and caplets or the flattest surface of a
tablet). As such, a single cassette is adapted to feed and guide a
range of sizes and shapes of discrete objects toward the exit. Only
a few standard cassettes sizes are thereby needed to accommodate
all discrete objects for which the counter is primarily adapted:
tablets, capsules, caplets, etc. In addition, the manufacture of
the cassettes is relatively inexpensive, as the primary material of
manufacture is plastic, and the cassette for an individual
prescription does not need to be custom manufactured.
[0051] Referring back to FIG. 5, the cassette 16 is provided with a
metal leaf spring 81 having an upturned gate portion 82 extending
into and blocking the exit hole 58 of the cassette. A means, e.g.,
a solenoid 83, is provided in the housing for automatically opening
the gate and permitting the tablets to exit the exit hole 58 of the
cassette 16. The solenoid 83 is mounted on a mounting bracket 99
and has a shaft 83a extending thereabove. The solenoid shaft 83a
preferably does not contact the gate to open the gate. Rather, a
magnet 83b is provided at the end of the shaft 83a. When the
solenoid 83 is actuated, the magnet 83b is moved closer to the leaf
spring 81 causing the leaf spring to deflect toward the magnet 83b
and pull the gate portion 82 from the exit hole 58 to permit the
release of tablets in the cassette (FIG. 11). Deactivation of the
solenoid 83 moves the magnet 83b further from the leaf spring 81
such that the bias of the leaf spring overcomes the force of the
magnet 83b, and the exit hole 58 is again closed by the gate
portion 82 (FIG. 5). Other magnetic, mechanical or
electromechanical elements or assemblies may alternatively be used
to close and open the exit hole of the cassette.
[0052] Referring to FIGS. 1 through 3 and 5, the cassette 16
preferably also includes two alignment posts 84, 85. The posts 84,
85 are preferably equally spaced apart about the exit hole 58. The
posts 84, 85 are preferably nondiametrically located, and most
preferably separated by approximately 1200. The posts are spaced to
align the cassette with the wall 124 on the housing (but preferably
not contact the wall) when the cassette 16 is placed on the upper
deck 120 (FIGS. 1 and 2). This ensures alignment of the exit hole
58 over the chute entrance 130.
[0053] Cassettes 16 are mounted to the mounting assembly 14 in a
manner which permits rapid and secure coupling and decoupling.
Preferred coupling means include electromagnetic coupling and
power-driven clamping systems. Referring to FIGS. 12 and 13, with
respect to an electromagnetic coupling, the mounting assembly 14
includes a base 86 provided with a preferably cylindrical
electromagnet 88 sized to fit snugly at least partially within the
hole 68 in the bottom of the cassette and provided adjacent the
metal plate 70. The cassette 16 is provided over the electromagnet
88, and the electromagnet is activated to cause a secure coupling
of the cassette thereto. Conversely, deactivation of the
electromagnet permits rapid decoupling of the cassette from the
mounting assembly. The base 86 preferably includes a plurality of
resilient ball plungers 90 adapted to force the bottom of the
cassette 16 from its snug fitting over the electromagnet 88 when
the electromagnetic is deactivated. The base 86 is also coupled to
two brackets 92 on opposite sides of the base adapted to couple the
base to the vibration system 12.
[0054] Still referring to FIGS. 12 and 13, the vibration system 12
includes two shaker elements (electromechanical vibrators known in
the art) 94 which are coupled to opposite side walls 96 of a rigid
U-shaped block 98. In turn, the brackets 92 of the mounting
assembly 14 are coupled between the shaker elements 94. The shaker
elements 94 are adapted to provide a horizontal circular vibratory
motion in the feed direction (FIG. 10) to the mounting assembly and
consequently to a cassette rigidly mounted on the mounting
assembly. The inertial block 98 is coupled by rubber shock mounts
100 to a support 102 within the housing. The shock mounts 100
substantially prevent vibratory energy from being transferred to
the housing 24.
[0055] In use, the reservoirs of a plurality of cassettes in a
pharmacy setting are each provided with the tablets of a different
prescription medicine. If it is then desired to count a fixed or
predetermined number (e.g., one hundred) of capsules 104 of a
particular prescription into a bottle, the cassette 16 containing
the particular prescription is provided on the mounting assembly 14
of the system. This is particularly done by providing the cassette
in the recess 128 in an orientation in which the alignment posts
align the cassette with the edges of the wall 124. The desired
number of capsules to be counted is then entered via the keypad 28,
a patient prescription bottle is placed adjacent exit spout 21, and
a start button on the keypad is activated. Operation of the start
button (1) provides electricity to the electromagnet 88 to
temporarily secure the cassette 16 thereon, (2) activates the
solenoid 83 to open the gate portion 82 of the leaf spring 81 on
the cassette, and (3) operates the vibration system 12 to initiate
vibration of the cassette. Referring to FIGS. 3, 8, 10 and 14, when
the cassette 16 is vibrated by the vibration system 12, capsules
104 in the reservoir 44 of the cassette are moved in the
counterclockwise feed direction through the opening 52 and the
narrow 53 (it being appreciated that for purposes of clarity far
fewer capsules than typically present are shown). The height H of
the opening 52 and size of the narrow 53 limits too many capsule
from entering the track area 54 at one time as the opening height
basically guarantees that the capsule will not exit the reservoir
in a stacked configuration while the narrow limits the number of
capsules simultaneously entering the track area. Referring to FIG.
14, the vibration urges capsules which have passed through the
narrow 53 and into the track area 54 to move toward the peripheral
wall 48 and into the channel 66. Generally, the capsules are
provided in a quantity to substantially fill the reservoir 44 and
crowd the track area 54. The channel 66 is sized to receive the
capsules 104 in a lengthwise orientation. The capsules 104 continue
in the channel 66 in a counterclockwise movement through the exit
guide 60 and are directed single file toward the exit 58. The
capsules fall through the exit 58, enter the chute 18, are each
counted by the object counting system 22, and are dispensed at the
spout 21 into a bottle (FIGS. 1 and 3). Capsules 104 which do not
exit the cassette 16 during a first pass around the track area 54
are guided back toward the narrow by the return guide 62. The
capsules 104 continue traveling around the track area 54 and
through the exit 58 until the selected number of capsules is
counted, as indicated by the display 26. Once the system has
counted the required number of capsules, the vibration stops, the
solenoid releases the gate, and the cassette is released from the
mounting assembly. With this system, objects can be fed and counted
relatively rapidly, typically from five to twenty per second.
[0056] According to a preferred aspect of the invention, when the
system has counted to near the required number, the vibration
system vibrates at a lower amplitude to slow down the rate of
counting. This feature substantially prevents overcounts which may
occur due to having counted the required number of capsules even
though uncounted capsules still exist in the space between the exit
hole 58 and the counting system 22. A slow down system is described
in detail in co-owned U.S. Pat. No. 5,473,703, which is hereby
incorporated by reference herein in its entirety.
[0057] A cassette can easily and rapidly be removed from the system
by removing the power to the electromagnet 88. The ball plungers 90
then push the cassette from over the electromagnet to facilitate
manual removal of the cassette from the mounting assembly. A second
cassette may then be placed over the electromagnet and power can
then be resupplied to the electromagnet to provide a very secure
coupling with the second cassette.
[0058] It is noted that in cassette 16, all tablets must travel in
single file through exit hole 58. As such, one limitation of the
cassette system is the speed at which tablets or other single dose
medications can be fed and exited into the chute for counting. In
view thereof, a second embodiment of a cassette adapted to feed
tablets more rapidly and yield greater system throughput is
provided. Turning now to FIGS. 15, 16 and 17, the second embodiment
of the cassette 216 generally includes a reservoir 244 which feeds
tablets and other single dose medication to two discrete trays
(levels) 254, 255. Each tray is provided with an exit hole 258, 259
which feeds the tablets into the chute 18 of the system 10. More
particularly, the cassette 216 includes a base 240 having an upper
surface defining the first tray 254, an intermediate shelf 241
having an upper surface defining the second tray 255, an annular
cover over the shelf 243, and a cylindrical element 242 over the
cover and which defines the reservoir portion 244. The base 240, as
shown in FIG. 16, is substantially similar to base 40 with the
following exception: a second hole 281, preferably walled-off from
exit hole 258 and the remainder of the first tray 254, is provided
preferably adjacent exit hole 258. The second hole 281 is provided
along the periphery of the tray and located counterclockwise from
the exit hole 258. Referring to FIG. 17, the shelf 241 is also
substantially similar to base 40 with the following exceptions.
First, exit hole 259 is aligned over the second hole 281 on the
first tray 254. Second, the shelf includes a relatively large
central opening 283 adapted to permit tablets in the reservoir 244
to pass therethrough and onto the first tray 254.
[0059] When tablets are provided into the reservoir, they naturally
stack substantially in the formation shown in broken lines in FIG.
15. As the cassette is vibrated, tablets move from the stack onto
the tray and shelf, and peripherally to the tracks 254, 255. From
the tracks, the tablets are fed toward the exit holes 258, 259.
Tablets exiting exit hole 258 fall directly into the entrance 130
of the chute 18. Tablets exiting exit hole 259 fall through hole
281 in the first tray and then into the chute 18. In order to close
the exit holes, two leaf spring gates 291, 293 are used. Opening of
the spring gates may be actuated by two solenoids provided in the
housing 24, each being to adapted to separately open one of the
gates. Alternatively, a single solenoid configured to open both
gates, e.g., having two arm portions coupled thereto, may be used
to operate both gates. Where two solenoids are used, it may be
preferable to have one of the solenoids operate to release and
close one of the gates when the number of counted tablets
approaches the number desired, leaving only one of the gates open.
This prevents two tablets from substantially simultaneously falling
into the chute (one from each exit hole) when only one additional
tablet is needed for a full count.
[0060] As stated above, the dual sensor array of previously
incorporated U.S. Pat. No. 5,768,327 is adapted to sense multiple
objects simultaneously falling passed the sensors. As such, it is
ideally suited to sense tablets exiting from the two-level
cassette.
[0061] The above cassette embodiments permit rapid dispensing of
medications stored in the cassettes. However, there may be
medications in a pharmacy which are used with an infrequency such
that cassette storage is not warranted. Therefore, turning now to
FIGS. 18 and 19, according to another aspect of the invention, the
system 10 may be used as a pour-through system. When a cassette 16,
216 is not located on the mounting assembly and the shield 132 is
removed from over the chute entrance 130, a funnel 134 into which
tablets may be poured is provided in the chute entrance. In this
pass-through configuration, no preset number is entered prior to
pouring tablets into the funnel. Rather, sensor 129 indicates that
a cassette is not being used, and the system 10 is automatically
adapted to count tablets passing through the funnel. The number of
tablets counted is displayed on the display 26.
[0062] Referring now to FIG. 20, according to another aspect of the
invention, a universal bowl feeder 316 can be attached to and
detached from the mounting assembly 14, preferably in the same
manner as the cassettes. As such, the bowl feeder 316 is made from
metal or made from plastic and provided with a metal insert or
bottom plate, as described with respect to the cassettes. This
enables the bottom 318 of the feeder 316 to be mounted to the
mounting assembly 14. The feeder 316 has a reservoir 320 which
holds tablets, and a ramp 322 designed to feed practically any size
or shape tablet or other single dose medication. Bowl feeders with
this interior design are available from Kirby Lester Inc. of
Stamford, Conn. Referring to FIGS. 4, 15 and 17, the bowl feeder
316 is positionable within the recess 128 such that the sensor 129
causes the system to enter preset counting mode. A desired number
of tablets is entered via the keypad 128, and a start button on the
keypad is then actuated causing the electromagnet of the mounting
assembly 14 to secure the feeder 316 thereto, and the vibration
system 16 to vibrate the feeder to feed tablets from the reservoir
320, up a the ramp 322, and to an exit 324, where the tablets fall
into the chute entrance 130 and are then counted by the object
counting system 22. The feeder accommodates prescriptions which are
not provided their own dedicated cassette, but for which a
pharmacist does not wish to manually feed tablets until a desired
number of tablets is counted.
[0063] There have been described and illustrated herein embodiments
of a cassette system for feeding, counting, and dispensing tablets,
capsules, caplets, and the like. While particular embodiments of
the invention have been described, it is not intended that the
invention be limited thereto, as it is intended that the invention
be as broad in scope as the art will allow and that the
specification be read likewise. Thus, while the system is described
as being suitable for manual cassette coupling and removal in a
pharmacy setting, it will be appreciated that the system may be
adapted for a robotic system in a pharmacy setting or otherwise. In
addition, while an electromagnetic mounting assembly is preferred,
it will be appreciated that other rapid and easy to use coupling
systems may also be used. For example, a preferably power-driven
mechanical coupling which threadably secures the cassette to the
mounting assembly can be used. Further, while cassettes with one
and two track layers have been described, it will likewise be
appreciated that cassettes with three or more track layers can
similarly be used to even more rapidly count tablets. Also, while
the feed direction is shown and described as being
counterclockwise, it will be appreciated that the shakers can be
configured to shake the cassette with clockwise motion, and the
guides, narrow, and, in one embodiment, two exit holes can be
configured to guide tablets in the clockwise direction toward the
exits. Further, while particular opening height and narrow
dimensions relative to the tablet size were disclosed as being
preferred, it will be appreciated that other dimensions could be
utilized. Also, while the system is stated to secure the cassette
and to the mounting assembly upon activation of a start button, it
will be appreciated that locking may occur based upon the sensor
recognizing a cassette or bowl feeder being placed on the mounting
assembly. In addition, the release of the gate by the solenoid and
the release of the cassette or bowl feeder from the mounting
assembly may be triggered by means other than described.
Furthermore, the funnel may be permanently coupled to the housing
in a manner which permits placement and removal of a cassette in
conjunction with the funnel. Also, the system may include a
two-layer cassette and have two separate feeds each having a
one-dimensional optical system for sensing tablets passing through
the feeds, the feeds then going to a common chute or exit spout. It
will therefore be appreciated by those skilled in the art that yet
other modifications could be made to the provided invention without
deviating from its spirit and scope as claimed.
* * * * *