U.S. patent application number 11/975859 was filed with the patent office on 2008-04-24 for method and apparatus for sorting, counting and packaging pharmaceutical drugs and other objects.
Invention is credited to Monroe T. Milton.
Application Number | 20080093372 11/975859 |
Document ID | / |
Family ID | 39316957 |
Filed Date | 2008-04-24 |
United States Patent
Application |
20080093372 |
Kind Code |
A1 |
Milton; Monroe T. |
April 24, 2008 |
Method and apparatus for sorting, counting and packaging
pharmaceutical drugs and other objects
Abstract
A method and apparatus is provided for handling loose objects
having different physical characteristics, such as pharmaceutical
drugs including, without limitation, oral solids in the form of
pills, tablets, capsules and the like. Loose objects are loaded
into individual canisters. A tooling assembly, comprising at least
one canister drive mechanism, imaging sensor and package handler is
mounted to a gantry assembly, can be translated through the cabinet
via the gantry assembly to engage with particular canisters in
accordance with unique and dynamic control parameters. Objects are
dispensed from a canister directly to the desired packaging, such
as a vial or "blister pack." Additionally, a beneficially stronger
blister pack container is provided.
Inventors: |
Milton; Monroe T.;
(Lecompte, LA) |
Correspondence
Address: |
Ted M. Anthony
P.O. Box 3408
Lafayette
LA
70502
US
|
Family ID: |
39316957 |
Appl. No.: |
11/975859 |
Filed: |
October 22, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60853698 |
Oct 23, 2006 |
|
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|
Current U.S.
Class: |
221/13 |
Current CPC
Class: |
B65B 5/103 20130101;
B65B 57/14 20130101; G07F 11/165 20130101; G07F 11/62 20130101;
B65B 1/04 20130101; G07F 17/0092 20130101; B65B 35/06 20130101 |
Class at
Publication: |
221/13 |
International
Class: |
B65B 57/00 20060101
B65B057/00 |
Claims
1. An apparatus for dispensing loose objects comprising: a) a
support frame; b) a plurality of canisters disposed within said
support frame; c) a rail assembly; d) a dispensing assembly movably
disposed on said rail assembly; and e) a processor for selectively
positioning said dispensing assembly adjacent to at least one
canister and dispensing loose objects from said at least one
canister.
2. The apparatus of claim 1, wherein said canisters are in a grid
pattern.
3. The apparatus of claim 2, wherein said canisters further
comprise: a) a housing; b) at least one opening in said housing; c)
at least one inclined baffle; d) a gate assembly; e) a ramp having
a first end and a second end, wherein said first end is pivotally
connected to said housing, and pivots about a horizontal axis; and
f) means for selectively raising and lowering said second end of
said ramp.
4. The apparatus of claim 3, wherein the upper surface of said ramp
defines a plurality of planes along the longitudinal axis of said
ramp.
5. The apparatus of claim 1, wherein said dispensing assembly
further comprises at least one actuator.
6. The apparatus of claim 1, wherein said dispensing assembly
further comprises at least one light.
7. The apparatus of claim 1, wherein said dispensing assembly
further comprises at lease one package holder.
8. The apparatus of claim 1, wherein said dispensing assembly
comprises at least one optical sensor.
9. An apparatus for dispensing loose objects comprising: a) a
support frame; b) a plurality of canisters disposed in a grid
pattern within said support frame, wherein such canisters comprise:
i. a housing; ii. at least one opening in said housing; iii. at
least one inclined baffle; iv. a gate assembly; v. a ramp having a
first end and a second end, wherein said first end is pivotally
connected to said housing, and pivots about a horizontal axis; and
vi. means for selectively raising and lowering said second end of
said ramp; c) a rail assembly; d) a dispensing assembly movably
disposed on said rail assembly; and e) a processor for selectively
positioning said dispensing assembly adjacent to at least one
canister and dispensing loose objects from said at least one
canister.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] THIS APPLICATION CLAIMS THE BENEFIT OF U.S. PROVISIONAL
PATENT APPLICATION Ser. No. 60/853,698, FILED Oct. 23, 2006
STATEMENTS AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY
SPONSORED RESEARCH AND DEVELOPMENT
[0002] NONE
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention pertains to a method and apparatus for
handling loose objects having different physical characteristics.
More particularly still, the present invention pertains to a method
and apparatus for storing, sorting, counting and packaging loose
objects, such as pharmaceutical drugs including, without
limitation, pills, tablets, capsules and the like. More
particularly still, the present invention pertains to a method and
apparatus for sorting, counting and packaging pharmaceutical drugs
having different physical characteristics including, without
limitation, sizes, shapes, textures, colors and/or weights.
[0005] 2. Brief Description of the Prior Art
[0006] Modern day pharmaceutical drugs--such as pills, tablets,
capsules and the like--exhibit a wide variety of physical
characteristics including, but not necessarily limited to, sizes,
geometries, textures, shapes, colors and weights. Storing,
handling, accounting for, and packaging of, such drugs have proven
to be a challenge for the pharmaceutical distribution industry.
Although such tasks have historically been performed manually, it
is widely recognized that effective automation of such tasks
greatly improves the overall cost, efficiency and accuracy of such
tasks.
[0007] Attempts have been made to automate various tasks associated
with the handling of pharmaceutical drugs. Such efforts have been
reasonably successful in certain limited circumstances; existing
automated pharmaceutical drug handling systems have yielded
passable results when only a single type of drug is being handled
and/or when equipment space is not an issue. For example, in the
bulk distribution scenario, large-scale equipment can be
specifically matched to a particular type of drug, operated for an
extended period, and then broken down and re-tooled before changing
to a different drug.
[0008] Unfortunately, existing automated handling systems have
proven to be inadequate when used to simultaneously handle multiple
pharmaceutical drugs (that is, pills, tablets, capsules, etc.)
having different physical characteristics, and/or when space for
automated handling equipment is limited. Such existing handling
systems typically utilize one or more of the following: [0009]
rotating slotted disks with slot dimensions matched to particular
pill dimensions; [0010] rotating slotted drums with slots matched
to particular pill dimensions; [0011] rotating wheels with vacuum
holes and adjustable sweepers set by the user to allow a single
pill to pass at a time; [0012] pressurized air to fluidize pills
(similar to a lotto or bingo machine); [0013] "v-shaped" vibratory
trays; [0014] augers that pull pills up an incline and are jogged
back and forth at pre-determined rates matched to a particular pill
characteristics so that pills singulate as they are fed up the
incline; and [0015] ribbed, rotating plates that move pills toward
the outer rim of such plates, and an adjustable sweeper to allow
only one pill at a time to be diverted from this rim to a drop-out
chute.
[0016] Existing automated handling devices, including those
described above, suffer from a number of very serious deficiencies.
Most existing automated systems cannot simultaneously account for
multiple pharmaceutical drugs having different physical
characteristics because automation hardware must be matched to a
specific type of drug being handled. At a minimum, such existing
systems must be frequently (and in some cases continuously)
adjusted in order to handle different drugs and obtain desired
levels of accuracy. Further, accuracy of such systems has not
proven to be reliable.
[0017] Importantly, because different drugs come in contact with
certain common elements of the handling equipment, existing
pharmaceutical handling systems can permit cross contamination.
Residue from one type of drug can be left behind on the equipment
surfaces encountered by the drugs being handled by such equipment.
The residue can then be picked up by other drugs coming in contact
with such equipment surfaces, thereby resulting in contamination of
such drugs. Additionally, most existing methods do not permit
packaging of sorted and/or counted drugs, and those that do allow
packaging of drugs do not permit counting of the drugs directly
into such packaging.
[0018] Existing drug handling systems also suffer from some
especially serious limitations during the packaging of
pharmaceutical drugs, particularly when such drugs are packaged in
sealed containers commonly referred to as "blister cards" or
"blister packs." Such existing automated drug packaging systems
frequently utilize a rotary drum or other counting system that
dispenses the counted objects into an external shuttle or other
device. The shuttle contents are then transferred into blister pack
trays. Such systems add an unnecessary step to the process between
the counting and packaging phases. This unnecessary step allows for
cross contamination, as drug, residue can collect on the shuttle
and be transferred to other drugs. Such systems yield generally
poor results, have large footprints and occupy an excessive amount
of space.
[0019] As a result of the aforementioned limitations, existing
automated pharmaceutical handling systems are not ideally suited to
serving the needs of Long Term Care (LTC) or retail pharmacies.
Such existing systems, and particularly those that include a
packaging function, are either too expensive or too bulky (or both)
for such applications. A relatively small and inexpensive automated
pharmaceutical handling system would reduce the labor burden on
technicians in LTC and retail pharmacies.
[0020] Thus, there is a need for an automated pharmaceutical
handling method and apparatus that can simultaneously handle
multiple drugs (that is, pills, tablets, capsules, etc.) having
different physical characteristics. The apparatus should be
relatively compact, such that it can be used in virtually any
environment including, without limitation, in pharmacies or other
areas where space is limited. The apparatus should permit isolation
of different drugs from one another to prevent cross contamination,
and should allow for accurate and efficient sorting, counting and
packaging of such drugs. The apparatus should also permit the
counting and packaging of such drugs in a single process to improve
accuracy and eliminate cross contamination. Further, the apparatus
should permit such drugs to be counted and/or dispensed directly
into packaging (such as, for example, vials, strip seal pouches,
blister pack trays or other packaging), as desired.
SUMMARY OF THE PRESENT INVENTION
[0021] The present invention comprises a method and apparatus for
automated handling of objects having different physical
characteristics, such as pharmaceutical drugs including, without
limitation, pills, tablets, capsules and the like, having multiple
sizes, geometries, textures, shapes, colors and/or weights. The
present invention permits the simultaneous storage, sorting and
counting of multiple objects. Further, the present invention
permits on-demand packaging of such objects, including the filling,
sealing, and labeling of blister packs, all utilizing a single
piece of equipment having minimal space and power requirements.
[0022] It should be noted that the present invention has a number
of advantages, and can be beneficially utilized in a number of
different applications. For ease of reference, the invention is
discussed herein primarily with respect to pharmaceutical drugs,
and in the context of the pharmaceutical distribution industry.
However, the description set forth herein is for illustration
purposes only, and is not intended to limit or otherwise restrict
the scope of the present invention in any way.
[0023] Although the method and apparatus of the present invention
can be used in any number of different applications, the invention
is particularly beneficial for pharmacies serving the LTC industry
and/or the retail market. LTC pharmacies frequently package a large
percentage of their prescriptions in a multi-dose (such as a
30-day) supply format such as sealed blister packs, while retail
pharmacies typically dispense their prescriptions in vials. The
present invention can fill, seal, and label sealed blister packs,
and/or dispense directly into vials, thereby relieving a
significant labor burden on pharmacy technicians.
[0024] The present invention broadly comprises a method and
apparatus for storing, sorting, metering and packaging objects such
as, for example, pharmaceutical drugs in pill form. In the
preferred embodiment, the present invention comprises at least one
cabinet member having a plurality of removable canisters
beneficially arrayed in a plurality of rows and columns, a motion
control system, a canister drive and control sub-system, an imaging
sub-system, a packaging sub-system, a processing sub-system and a
power sub-system.
[0025] The present invention further comprises a method for
positioning a canister drive mechanism, sensing apparatus and
package handler proximate to particular canisters, as desired, to
address such canisters in accordance with unique and dynamic
control parameters. In the preferred embodiment of the present
invention, at least one canister drive mechanism, imaging sensor,
and package handler are disposed on end-of-arm tooling disposed on
a Cartesian robot, which is in the form of an automated gantry
assembly. Such components translate through the cabinet via said
Cartesian robot to engage the particular canister(s) containing
desired objects (pills).
[0026] Each removable canister in the cabinet comprises a container
having at least two distinct areas, one for bulk pill storage and
another for pill flow control. Pills are loaded into the bulk
storage area of each removable canister to be utilized; in most
cases, only a single type of pill is loaded into a canister at a
particular time. In the preferred embodiment, each canister
contains a plurality of surfaces in the bulk storage area of said
canister to permit gravity feeding of the stored pills to a
metering device. The metering device, which is located near the
lower portion of the bulk storage area, ensures a controlled flow
of pills onto a flow control ramp. Importantly, the pills contained
within each canister only come in contact with certain internal
surfaces of that particular canister, and the contents of the
different removable canisters remain isolated from each other,
thereby preventing cross contamination of pills.
[0027] In the preferred embodiment, each canister of the present
invention further includes a flow control device. Said flow control
device generally comprises a ramp having a continuous multi-planar
surface for imparting energy onto pills situated on said ramp, and
facilitating the feed forward control process of the system. Each
ramp has a concave cross-section along its width and a convex
planar cross-section along its length. The concave cross-section
promotes end-to-end alignment of pills, while the convex
cross-section acts to accelerate the pills in direction of flow in
order to control separation of pills. The multi-planar ramp defines
a step (drop) from one section to another along a substantially
continuous surface, is less abusive to the pills situated thereon
compared to other handling devices, and promotes singulation and
separation of such pills.
[0028] In the preferred embodiment, the ramp is vibrated to impart
energy on the pills situated on said ramp. Specifically, the ramp
surface is vibrated along the longitudinal axis of said ramp, with
dynamic close loop control of the amplitude and frequency of such
vibration, to control orientation and flow of pills situated on
said ramp. Additionally, the horizontal orientation of the
longitudinal axis of the ramp is dynamically adjustable (that is,
the inclination or declination of the ramp can be dynamically
adjusted) so that gravitational force is used to increase or
decrease pill separation and flow direction of pills situated on
said ramp.
[0029] The present invention utilizes a machine vision based
imaging sensor for closed-loop control of pill flow. Said imaging
sensor permits implementation of feed forward control logic to
react to problems in real-time before pills are actually dispensed.
Specifically, the present invention utilizes an area imaging object
sensor to track pills at certain critical stages as such pills
transition through the apparatus including, without limitation, on
the ramp of each canister. Information obtained from imaging
scanner is sent to at least one processor that controls various
elements of the present invention including, without limitation,
actuators that adjust ramp inclination and vibration. Such area
imaging object sensor provides increased control and management of
the pills throughout the handling process.
[0030] One embodiment of the imaging system of the present
invention utilizes a reflective imaging device capable of
controlling a plurality of light emitting devices over a range of
different wavelengths. The reflected energy is mechanically and
electronically filtered in order to track the pills. In another
embodiment, the imaging system of the present invention comprises a
translucent rear illuminated surface for silhouetting pills in
flow. The use of back lighting allows for maximum contrast and
improved pill tracking.
[0031] The present invention utilizes at least one processor to
implement a method of feed forward control logic to expedite the
filling of different pharmacy packaging with a common canister and
control. With closed loop control on all drive components
associated with pill flow and packaging positing, preemptive logic
improves the delivery and accuracy of the overall filling
process.
[0032] The term open loop control generally refers to systems
wherein output is not measured. Such systems are operated using
consistent input parameters without measuring whether such
parameters are actually achieved. Such systems can become unstable
thereby allowing too many, or too few, objects to flow. By
contrast, closed loop systems (such as the system employed by
present invention) use measured feedback to dynamically adjust the
input values and maintain the desired output levels. Closed loop
systems frequently utilize an encoder tied to a drive motor, such
that output can be measured and input voltage can be dynamically
adjusted. Improved control allows designers to ensure consistent
operational parameters over the life of the product and across
manufactured systems.
[0033] The feed forward control processes of the present invention
utilize anticipatory logic for future events to increase the
overall efficiency and control of the system. Use of closed loop
motion control with feed forward system control allows for
increased accuracy and reduced cycle time by dynamically adjusting
systems to account for object flow.
[0034] The present invention further comprises a novel blister card
design from film with sufficient stiffness so that additional
laminate packaging layers, such as cardboard sheets and the like
that are frequently required to provide rigidity, are not required.
An embodiment demonstrates the effective use of an interlocking
blister card to prevent the propagation of bend lines, thus
allowing for the reduction of material layers. Such blister cards
can be embossed with characters formed into blisters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The foregoing summary, as well as the following detailed
description of the preferred embodiments, is better understood when
read in conjunction with the appended drawings. For the purpose of
illustrating the invention, the drawings show certain preferred
embodiments. It is understood, however, that the invention is not
limited to the specific methods and devices disclosed.
[0036] FIG. 1 depicts a front view of one embodiment of a cabinet
of the present invention.
[0037] FIG. 1A depicts a side view of the cabinet embodiment
depicted in FIG. 1.
[0038] FIG. 2 depicts a front view of an alternative embodiment of
a cabinet of the present invention.
[0039] FIG. 2A depicts a side view of the cabinet embodiment
depicted in FIG. 2.
[0040] FIG. 3 depicts a side perspective view of the apparatus of
the present invention with supporting cabinet enclosure
removed.
[0041] FIG. 4 depicts a side perspective view of a canister of the
present invention.
[0042] FIG. 5 depicts a side perspective cut-away view of a
canister of the present invention.
[0043] FIG. 6 depicts a side cut-away view of a canister of the
present invention.
[0044] FIG. 7 depicts a perspective view of a multi-planar ramp of
the present invention.
[0045] FIG. 8 depicts a front view of a multi-planar ramp of the
present invention.
[0046] FIG. 9 depicts a side view of a multi-planar ramp of the
present invention.
[0047] FIG. 10 depicts a side view of a multi-planar ramp of the
present invention in raised and lowered positions.
[0048] FIGS. 11 through 14 depict side views of a multi-planar ramp
of the present invention having loose objects disposed on the upper
surface of said ramp.
[0049] FIG. 15 depicts a side perspective view of an end-of-arm
tooling assembly of the present invention engaged with a canister
of the present invention.
[0050] FIG. 16 depicts front view of an end-of-arm tooling assembly
of the present invention engaged with a canister of the present
invention.
[0051] FIG. 17 depicts a side perspective view of an end-of-arm
tooling assembly of the present invention holding a blister pack
tray.
[0052] FIG. 18 depicts an end view of an end-of-arm tooling
assembly of the present invention holding a blister pack tray.
[0053] FIG. 19 depicts a side perspective view of an end-of-arm
tooling assembly of the present invention holding a vial.
[0054] FIG. 20 depicts a side cut away view of an end-of-arm
tooling assembly of the present invention holding a vial and
engaged with a canister of the present invention.
[0055] FIG. 21 depicts an overhead view of a prior art blister pack
tray.
[0056] FIG. 21A depicts a side view of the existing prior art
blister pack tray depicted in FIG. 21.
[0057] FIG. 22 depicts a side view of the prior art blister pack
tray depicted in FIGS. 21 and 21A exposed to bending forces.
[0058] FIG. 23 depicts an overhead view of an improved blister pack
tray of the present invention.
[0059] FIG. 23A depicts a side view of the improved blister pack
tray of the present invention depicted in FIG. 23.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
[0060] The present invention has a number of advantages, and can be
beneficially utilized in a number of different applications
involving the sorting, counting and/or packaging of loose objects.
For ease of reference, the present invention is described herein
primarily in connection with applications involving pharmaceutical
drugs and other substances, and especially drugs and other
substances delivered in the form of oral solids. The description
set forth herein is for illustration purposes only, and is not
intended to limit or otherwise restrict the scope of the present
invention in any way. For illustration purposes, the present
invention is described in connection with the handling of pills;
however, it is to be observed that the present invention can be
used with a multitude of other oral solids or loose objects.
[0061] The present invention broadly comprises a method and
apparatus for storing, sorting, counting and packaging loose
objects such as, for example, pharmaceutical drugs in pill, tablet
and/or capsule form. Referring to the drawings, FIG. 1 depicts a
front view of a cabinet member 10 of the present invention, while
FIG. 1A depicts a side view of said cabinet member 10. It is to be
observed that the specific design parameters of said cabinet member
10 can be varied to meet particular needs. As a result, said
cabinet member 10 can be manufactured having a wide range of
shapes, sizes and/or configurations depending upon the intended use
of the present invention, as well as the specific environment in
which the present invention is to be utilized. Still referring to
FIG. 1, cabinet member 10 generally comprises a plurality of
removable canisters 100 disposed within external cabinet support
frame 11. Cabinet member 10 further comprises processing/control
module 40 and packaging module 50. Such components are generally
depicted in FIG. 1A as well, except for canisters 100 which are
obscured from view in FIG. 1A.
[0062] FIGS. 2 and 2A depict front and side views, respectively, of
an alternative embodiment of cabinet member 10 of the present
invention. The embodiment depicted in FIGS. 2 and 2A are similar to
the embodiments depicted in FIGS. 1 and 1A, except that cabinet
member 10 has a single array of canisters 100, and a vertical
layout of packaging module 50. By contrast, in the embodiment
depicted in FIGS. 1 and 1A, cabinet member 10 has two distinct
grids of canisters 100, and a horizontal orientation of packaging
module 50. In many cases, the specific layout of the individual
components of the present invention (including, but not necessarily
limited to, canisters 100, processing/control module 40 and
packaging module 50) in support frame 11 of cabinet member 10 will
be dictated by a number of factors related to the specific
application in which the apparatus will be utilized. Such factors
include, without limitation, the type of pills being handled, the
location and/or environment in which said cabinet will be employed,
and/or the particular type of prescription container that an
application will support.
[0063] In most cases, cabinet member 10 of the present invention is
beneficially tailored to best accommodate its intended use. By way
of illustration, but not limitation, when the apparatus of the
present invention is to be utilized in an LTC or retail pharmacy
setting (or any other location where space may be limited) it is
generally beneficial that support frame 11 of said cabinet be
relatively compact with a small footprint requiring minimal floor
space.
[0064] FIG. 3 depicts a side perspective view of the apparatus of
the present invention generally depicted in FIG. 2, external
cabinet support frame 11 removed. Referring to FIG. 3, removable
canisters 100 are beneficially arrayed in a grid pattern defining a
plurality of rows and columns. Automated gantry assembly 20, which
comprises a plurality of elongate and slidably connected rails,
such as vertical rail 21 and horizontal rail 22, is powered by
drive motor assembly 23 and is mounted in general proximity to one
face of said canisters 100. In the preferred embodiment of the
present invention, said automated gantry assembly 20 comprises a
Cartesian robot assembly of a type that is well known to those
having ordinary skill in the art. In the preferred embodiment, said
automated gantry assembly 20 is used to position components of the
present invention proximate to particular canisters 100, as
desired, in order to address and engage such canisters in
accordance with unique and dynamic control parameters.
Specifically, such components are translated through cabinet member
10 within support frame 11 (not depicted in FIG. 3) via automated
gantry assembly 20 to engage with particular canister(s) 100
containing desired loose objects (such as, for example, pills) to
be sorted, counted and/or packaged in accordance with the present
invention.
[0065] Still referring to FIG. 3, packaging module 50 may comprise
a number of different components depending upon different
application variables including, without limitation, the type of
packaging to be utilized in a particular situation. However, in the
preferred embodiment of the present invention, packaging module 50
will typically beneficially include one or more of the following
components: container stock storage bin 51, sealing and labeling
module 52, sealing stock storage 53 and sealed package output
54.
[0066] Still referring to FIG. 3, automated gantry assembly 20 is
beneficially utilized to translate end-of-arm tooling assembly 300
to desired locations within external cabinet support frame 11 of
cabinet member 10 (not depicted in FIG. 3). In many applications,
automated gantry assembly 20 will first translate end-of-arm
tooling assembly 300 to prescription container stock storage bin 51
to retrieve an empty prescription container. After securing an
empty container, end-of arm tooling assembly 300 is translated to a
desired canister 100 via automated gantry assembly 20, and engaged
with said canister for dispensing of particular pills directly into
said container in accordance with the teachings of the present
invention. When dispensing operations are completed, end-of-arm
tooling assembly 300 disengages from said engaged canister 100, and
thereafter deposits a filled container in the sealing and labeling
module 52. Said filled container can be sealed and labeled in
module 52. Thereafter, the filled and sealed container is then
deposited in sealed package output component 54 for further
handling. The aforementioned basic process can be repeated for each
fill request.
[0067] When loose objects are packaged using blister packs, sealing
and labeling module 52 of the present invention can be utilized to
perform the sealing and labeling operations of the present
invention. In most cases, blister packs comprise a molded film tray
having a plurality of spaced indentions. Pills are deposited within
such indentions of such film tray containers as more fully set
forth herein. Thereafter, automated gantry assembly 20 translates
said filled tray to said sealing and labeling module 52. In most
cases, a foil cover is thereafter placed over and secured to said
film tray, and secured using a cold seal adhesive to enclose said
pills within the filled blister pack tray. Frequently, a roller is
also used to apply pressure to said foil cover to ensure proper
adhesion of such foil to said film tray container. After the foil
cover is applied, a prescription label containing required
information can be printed and placed onto the sealed blister pack.
Thereafter, said automated gantry assembly 200 can be used to
transfer said sealed and labeled blister pack to sealed package
output component 54 for further handling.
[0068] In the preferred embodiment, end-of-arm tooling assembly 300
of the present invention comprises a plurality of components.
Referring briefly to FIG. 19, such components may include at least
one of each of the following: at least one actuator 310, at least
one light source 320, imaging sensor assembly 330, drive links 340,
and prescription container holder 350.
[0069] Referring to FIG. 3, each removable canister 100 in cabinet
member 10 generally comprises a separate storage container for the
segregated storage of loose objects. Each container 100 comprises
at least two distinct regions: one region for bulk pill storage and
another region for pill flow control. Pills are loaded into the
bulk storage region of each removable canister 100 to be utilized;
in most cases, only a single type of pill is loaded into a
particular canister at a particular time.
[0070] FIG. 4 depicts a side perspective view of canister 100 of
the present invention. Canister 100 generally comprises canister
housing 101 having loading opening 120. Canister housing 101 acts
to protect pills contained within said canister 100 from
unauthorized removal, moisture, ultraviolet penetration, and/or
other contamination or spoilage. Pills can be loaded into canister
100 through opening 120, which is equipped with replenishment door
102. Replenishment door 102 is slidably mounted to canister housing
101, and can be beneficially locked to canister housing 101 for
prevention of unauthorized entry into canister 100. Replenishment
door 102 can also form a pressure seal against canister housing 101
to prevent air exchange. In the preferred embodiment of the present
invention, replenishment door 102 is situated on the upper surface
of canister housing 101 and maintains a substantially "flush"
profile with the upper surface of said canister housing 101.
Importantly, pills contained within a particular canister 100 only
contact certain internal surfaces of that particular canister,
while the contents of the other canisters remain completely
isolated from such pills. As a result, pills or pill residue from
one canister do not contact contents of another canister. The
design of the present invention serves to prevent cross
contamination of contents when different substances (such as, for
example, multiple types of different drugs) are simultaneously
stored and/or handled by said invention.
[0071] Still referring to FIG. 4, canister 100 also includes
external drive sockets 111, optional label surface 113 and light
pipe interfaces 322. Canister 100 further comprises opening 121 for
the dispensing of loose objects from said canister. Multi-planar
ramp, which is described in detail below, is disposed within
canister housing 101. In the preferred embodiment, front end 204 of
multi-planar ramp 200 (defining drip-off point 203, described
below) is disposed in close proximity to opening 121 in canister
housing 101.
[0072] FIG. 5 depicts a perspective cut-away view of canister 100
of the present invention. In the preferred embodiment, each
canister 100 contains a plurality of cooperating components and
surfaces situated within canister housing 101 that facilitate
gravity feeding of loose objects (such as pills) stored within each
such canister 100. Still referring to FIG. 5, pills loaded within
canister housing 101 through opening 120 are permitted to migrate
along inclined upper baffle 103. Said pills travel from upper
baffle 103 to inclined lower baffle 104, and thereafter onto bulk
metering ramp 105. When canister 100 is engaged by end-of-arm
tooling assembly 300, energy can be supplied to canister 100 to
vibrate upper baffle 103 and lower baffle 104. Baffle link 110
connects upper baffle 103 to lower baffle 104, and serves to
transfer such vibratory energy between said upper and lower
baffles. After pills within canister 100 reach bulk meter ramp 105,
flow of such pills is beneficially controlled by bulk meter gate
106. Bulk meter gate 106 permits a controlled number of pills onto
ramp 200, thus preventing an over-supply of pills on ramp 200.
[0073] Bulk meter gate 106 ensures a controlled flow of pills onto
ramp 200. Pill motion on ramp 200 is observed by an imaging sensor
assembly disposed on end-of-arm tooling assembly 300 (not shown in
FIG. 5). In the preferred embodiment, said imaging sensor utilizes
machine vision to account for objects in the imaging area. The
imaging sensor monitors the results of actuating bulk meter gate
106, allowing closed loop control of such actuation. The use of
said imaging sensor assembly, adjustable multi-planar ramp 200, and
a closed loop feed forward control logic further permit the
controlled flow of pills situated on the upper surface of said ramp
200.
[0074] In the preferred embodiment, ramp 200 has a continuous
multi-planar upper surface to impart energy onto pills situated on
said ramp 200, and to facilitate the feed forward control logic of
the system. Ramp 200 generally has a substantially concave
cross-section across its width and a substantially convex planar
cross-section across its length. The concave cross-section promotes
end-to-end alignment of pills on the upper surface of said ramp,
while said convex cross-section acts to accelerate the pills in a
desired direction in order to control separation of pills. The
multi-planar surface of ramp 200 defines a step (drop) from one
section to another section along a continuous surface, is less
abusive to the pills situated on said ramp compared to other
handling devices, and promotes singulation and separation of pills
on said ramp 200.
[0075] FIG. 6 depicts a side cut away view of canister 100 of the
present invention. Referring to FIG. 6, inclined upper baffle 103
is pivotally connected to the inner surface of canister housing 101
using upper pivot pin 107. Similarly, inclined lower baffle 104 is
pivotally connected to the inner surface of canister housing 101
using lower pivot pin 108. Baffle link 110 connects upper baffle
103 to lower baffle 104. In the preferred embodiment, bulk metering
ramp 105 has inclined upper surface 105a defining a pitch that is
oriented perpendicular to the longitudinal axis of said ramp. Said
bulk metering ramp 105 is further pivotally attached to the inner
surface of canister 101 using metering pivot pin 109. Bulk meter
gate 106 is connected to the distal end of lower baffle 104
(opposite lower pivot pin 108) via slotted mounting bracket 112,
and limits the flow of pills onto ramp 200. Ramp 200 is pivotally
mounted to canister housing 101 at forward end 205, and pivots
about a horizontal axis oriented perpendicular to the longitudinal
axis of ramp 200. End 205 of ramp 200 is not mounted, and is free
to travel along an arc, thereby permitting the incline angle of
ramp 200 to be adjustable.
[0076] Referring to FIG. 7, ramp 200 has forward end 204 and free
end 205. Ramp 200 further has a substantially concave cross
sectional profile across its width, and a substantially convex
cross sectional profile along its longitudinal axis. Across its
width, cross section of ramp 200 forms a continuous concave surface
(in the preferred embodiment, using a plurality of intersecting
planes) for promoting flow of pills toward the lower portion of
said cross section. Said cross section can be in the form of a
two-plane ("V-shape") cross section, or other effective shape, such
as a smooth and continuously curved concave parabola. When mounted
within a canister 100, ramp 200 pivots near end 204 about a
rotational axis passing through cylindrical mounting pins 210.
Referring to FIG. 8, which depicts a front view of multi-planar
ramp 200, the longitudinal axis of ramp 200 comprises a plurality
of inclined surfaces arrayed to form a continuous, but
substantially convex, upper surface. Generally, the angular
difference between the different inclined surfaces of ramp 200
permit the control system of the present invention to effectively
manage pill separation and velocity (speed and direction) through
dynamic adjustment of the incline of ramp 200.
[0077] FIG. 9 depicts a side view of multi-planar ramp having front
end 204 and free end 205. In the preferred embodiment, ramp 200 of
the present invention comprises a plurality of distinct zones. Zone
A is situated at the leading edge of ramp 200 nearest drop-off
point 203, which permits control of pill trajectory as pills depart
ramp 200. Zone A of ramp 200 has beneficial profile 201, such that
the exit angle of said ramp remains substantially consistent over
the rotational limits of ramp 200 as said ramp pivots about
cylindrical mounting pins 210. FIG. 10, which depicts a comparison
view of ramp 200 in both raised and lowered positions, illustrates
how the profile of ramp 200 can minimize the trajectory migration
of pills depending upon the incline angle of said ramp 200. For
purposes of the discussion, trajectory migration represents the
difference between raised ramp trajectory and a lowered ramp
trajectory for a given drop height, where said drop height is
defined as the distance from drop-off point 203 at end 204 of ramp
200, to the top of a receiving container held by end-of-arm tooling
assembly 300.
[0078] Referring back to FIG. 9, multi-planar upper surface of ramp
200 further defines Zone B, Zone C and Zone D. In the preferred
embodiment, said zones have linear cross sections with a decreasing
surface angle relative to level reference "x". Thus, Angle B is
greater than Angle C, which is in turn greater than Angle D. Using
such a decreasing relationship of zone angles, the control system
of the present invention can effectively manage flow of loose
objects, such as pills.
[0079] FIGS. 11 through 14 illustrate pills 1 and 2 moving in train
toward drop-off point 203 at forward end of ramp 200. Referring to
FIG. 11, pill 1 accelerates at a different rate than pill 2 due to
the surface angle difference on ramp 200. Referring to FIG. 12,
both pill 1 and pill 2 are situated in the same zone along the
upper surface of ramp 200 (Zone C shown on FIG. 9) and accelerating
at the same rate; however, the velocity of pill 1 is greater than
the velocity of pill 2 due to the increased time at Zone C's
acceleration. Spacing between pill 1 and pill 2 is tracked along
ramp 200, and when the minimum required spacing is maintained, the
orientation of ramp 200 is not adjusted. However, when minimum
required spacing between pill 1 and pill 2 is not maintained,
corrective action is implemented by dynamic adjustment to the
inclination of ramp 200. As FIG. 13 illustrates, ramp 200 can be
oriented so that pill 1 travels in one flow direction, while pill 2
travels in the opposite flow direction. Once minimum spacing
between pills 1 and 2 is obtained and observed, orientation of ramp
200 is returned to the position depicted in FIG. 14, thereby
allowing both pill 1 and 2 to beneficially travel in the desired
flow direction. The present invention also uses application of
vibratory energy to ramp 200 along the longitudinal axis of said
ramp to promote the desired flow of pills along the upper surface
of said ramp.
[0080] In the preferred embodiment, ramp 200 is vibrated to impart
energy on the objects situated on the upper surface of said ramp.
Specifically, the ramp surface is vibrated along the longitudinal
axis of said ramp, with dynamic close loop control of the amplitude
and/or frequency of such vibration, to control orientation and flow
of objects situated on said ramp 200. Additionally, the inclination
of ramp 200 is dynamically adjustable so that gravitational force
can be used to increase or decrease separation and flow direction
of objects situated on said ramp.
[0081] The present invention utilizes a machine vision-based
imaging sensor for closed-loop control of pill flow including,
without limitation, flow of pills situated on the upper surface of
ramp 200. Said imaging sensor is used to gather information
regarding pill placement. Such information is conveyed to a
computer processor, which in turn implements feed forward control
logic to react to problems in real-time before pills are actually
dispensed from a canister 100. With closed loop control on all
drive components associated with pill flow and packaging,
preemptive logic improves the delivery and accuracy of the overall
handling process.
[0082] One embodiment of the imaging system of the present
invention utilizes a reflective imaging device capable of
controlling a plurality of light emitting devices over a range of
different wavelengths. The reflected energy is mechanically and
electronically filtered in order to track objects. In another
embodiment, the imaging system of the present invention comprises a
translucent rear illuminated surface for silhouetting objects in
flow. The use of back lighting allows for maximum contrast and
improved object tracking.
[0083] FIG. 15 depicts a perspective view of the components of
end-of-arm tooling assembly 300 engaged with canister 100. In the
preferred embodiment, actuators 310, light source 320, imaging
sensor assembly 330, drive links 340 and container holder 350 (not
shown) are disposed on the end-of-arm tooling assembly 300. Said
end-of-arm tooling assembly 300 is translated proximate to a
particular canister (containing a desired type of pills) using a
gantry assembly as described above.
[0084] Referring to FIG. 15, end-of-arm tooling assembly 300
engages with a canister 100. Light source 320 directs light into
light pipe 321 (depicted in FIG. 6) via light pipe interfaces
(depicted in FIG. 4), thereby permitting transmission of light into
canister 100. Such light from light source 320 permits illumination
of ramp 200 with different light wavelengths. By way of example,
but not limitation, such wavelengths can include white light at
approximately 5500K, red light at approximately 630 nm, blue light
at 470 nm, green light at approximately 525 nm and infrared at
approximately 940 nm. The ability to dynamically change light
wavelength allows the present invention to utilize the wavelength
best suited for imaging the particular objects (pills) handled by
the present invention.
[0085] Sensor assembly 330 electronically and mechanically filters
incoming light to determine the optimum setting for tracking pills
as said pills flow along the upper surface of ramp 200. In order to
manage pill flow, the processing system of the present invention
utilizes information obtained from sensor assembly 330 to compute
the size and position of pills on ramp 200, confirm or deny pill
placement and, if necessary, take corrective action. Frequently,
such corrective action comprises transfer of mechanical energy to
canister 100 by actuators 310 disposed on end-of-arm tooling
assembly 300. Energy is transferred from said actuators 310 to
canister 100 and its various components using actuator drive arms
311, which are connected to drive links 340. Said drive links 340
engage drive sockets 111 of canister 100 (depicted in FIGS. 4 and
5) to transfer mechanical energy to the components of canister 100
including, without limitation, ramp 200.
[0086] FIG. 16 depicts front view of an end-of-arm tooling assembly
of the present invention engaged with a canister of the present
invention. Input ports 312 are provided on actuators 310, and allow
data transfer from to said actuators to facilitate the feed forward
control logic of the present invention. Actuator drive arms 311
mate with drive links to transmit energy to the components of
canister 100.
[0087] FIG. 17 depicts a side perspective view of an end-of-arm
tooling assembly 300 of the present invention holding a blister
pack tray 400 having a plurality of indentions 401 in packaging
holder 350. End-of-arm tooling assembly 300 has optional handle
360. FIG. 18 depicts an end view of said end-of-arm tooling
assembly of the present invention holding blister pack tray
400.
[0088] FIG. 19 depicts a side perspective view of an alternative
embodiment of end-of-arm tooling assembly of the present invention
holding vial 500 in vial holder 351. FIG. 20 depicts a side cut
away view of an end-of-arm tooling assembly 300 holding vial 500 in
vial holder 351, and engaged with canister 100 of the present
invention.
[0089] As the loose objects (such as pills) flow through the region
of interest on the upper surface of ramp 200, the contrast between
such objects and the background allows the sensor to define object
cross-section, and track each object. Reliability is improved when
a color spectrum comparison and relative size comparison is
conducted. In order to overcome reflectivity issues, the imaging
sensor allows for the range of the color spectrum (visible and
non-visible) to be used without hardware replacement. Varying the
light source intensity and spectrum as needed allows the imaging
sensor of the present invention to tune each counting sequence to
the optimal conditions, improving effectiveness and enhancing
object delivery.
[0090] A normal variant of reflective imaging is to back light the
region of interest to produce an increased contrast, thus allowing
for a less expensive imaging sensor to be deployed. Placing a light
source behind the region of interest allows light to reach the
imaging sensor of the present invention with full intensity. Such
light is blocked when an object travels through the area of
interest, thus allowing the image sensor the ability to define the
object's cross-section and track.
[0091] A significant advantage of the present invention is found in
the design of canister 100 and the means by which pills are
controlled and counted directly from canister 100 into a
prescription container (such as, for example, a blister pack or
conventional vial) without any additional step or device for
temporary storage of such pills.
[0092] FIG. 21 depicts an overhead view of a prior art blister pack
tray, while FIG. 21A depicts a side view of the existing prior art
blister pack tray depicted in FIG. 21. Existing prior art blister
packaging typically comprises a film container base or tray 410
having a plurality of indentions or "blisters" 411 for receiving
pills or other loose objects. Such conventional indentions are
frequently arrayed in rows and columns. Frequently, such film
containers lack desired stiffness or rigidity, and are susceptible
to bending forces as depicted in FIG. 22, particularly in the
regions between such rows and columns. As a result, prior art
blister packs are frequently packaged in a cardboard clamshell or
other similar device to stiffen the packaging while protecting the
relatively frail film and foil.
[0093] FIG. 23 depicts an overhead view of an alternative blister
tray 400 of the present invention having interlocking indentations
or blisters 401 to increase stiffness while not compromising the
sealing web. FIG. 23A depicts a side view of the blister design
illustrated in FIG. 23. The alternative interlocking blister design
of the present invention eliminates unsupported bend lines,
resulting in a reduction of film deflection and an increase in
overall rigidity of blister tray 400.
[0094] Blister tray 400 depicted in FIGS. 23 and 23A allows a
single film layer to be constructed in a manner that increases the
overall packing volume of pills (or other packaged loose objects)
by arraying blisters in an interlocking pattern. The pattern layout
ensures seal width is maintained for all blisters by decreasing
wasted seal space between indentations. Such minimization of wasted
seal space allows for a larger cross section to be obtained for
each blister, thus supporting lager objects, or an increased number
of objects in each blister. Additionally the interlocking pattern
stiffens the film container by preventing bend line propagation
between blisters.
[0095] The above-described invention has a number of particular
features that should preferably be employed in combination,
although each is useful separately without departure from the scope
of the invention. While the preferred embodiment of the present
invention is shown and described herein, it will be understood that
the invention may be embodied otherwise than herein specifically
illustrated or described, and that certain changes in form and
arrangement of parts and the specific manner of practicing the
invention may be made within the underlying idea or principles of
the invention.
* * * * *