U.S. patent application number 11/599576 was filed with the patent office on 2008-05-15 for device and method for labeling vials useful in system for dispensing prescriptions.
Invention is credited to Steve Bouchelle, Jasper Pollard.
Application Number | 20080110555 11/599576 |
Document ID | / |
Family ID | 38626897 |
Filed Date | 2008-05-15 |
United States Patent
Application |
20080110555 |
Kind Code |
A1 |
Bouchelle; Steve ; et
al. |
May 15, 2008 |
Device and method for labeling vials useful in system for
dispensing prescriptions
Abstract
An apparatus for applying a label to a pharmaceutical vial
includes: a base having a receiving section, a labeling section,
and a pick-up section; an index member attached to the base, the
index member including a receiving compartment, the index member
configured to receive a vial from a vial dispenser in the receiving
compartment as the receiving section is positioned over the
receiving section and convey the vial to the labeling section of
the base; a label source positioned to present a label to a vial
located in the labeling section of the base; and a labeling
assembly mounted in the labeling section of the base, the labeling
assembly configured to receive the vial from the index member and
apply the label to the vial. The index member is further configured
to convey the labeled vial from the labeling section to the pick-up
section.
Inventors: |
Bouchelle; Steve; (Raleigh,
NC) ; Pollard; Jasper; (Durham, NC) |
Correspondence
Address: |
MYERS BIGEL SIBLEY & SAJOVEC
PO BOX 37428
RALEIGH
NC
27627
US
|
Family ID: |
38626897 |
Appl. No.: |
11/599576 |
Filed: |
November 14, 2006 |
Current U.S.
Class: |
156/230 ;
156/567 |
Current CPC
Class: |
Y10T 156/1771 20150115;
B65C 9/32 20130101; Y10T 156/1705 20150115; Y10T 156/10 20150115;
B65C 9/02 20130101; B65C 3/16 20130101 |
Class at
Publication: |
156/230 ;
156/567 |
International
Class: |
B65C 9/04 20060101
B65C009/04 |
Claims
1. An apparatus for applying a label to a pharmaceutical vial,
comprising: a base having a receiving section and a labeling
section; an index member attached to the base, the index member
including a receiving compartment, the index member configured to
receive a vial in the receiving compartment as the receiving
compartment is positioned over the receiving section and convey the
vial to the labeling section of the base; a label source positioned
to present a label to a vial located in the labeling section of the
base; and a labeling assembly mounted in the labeling section of
the base, the labeling assembly configured to receive the vial from
the index member and rotate the vial as the label is presented to
the vial to apply the label to the vial.
2. The apparatus defined in claim 1, wherein the index member is
configured to convey a labeled vial from the labeling section to a
pick-up section.
3. The apparatus defined in claim 1, wherein the index member is
rotatably mounted to the base.
4. The apparatus defined in claim 1, wherein the index member is
configured to contact the vial and slide the vial across the base
from the receiving section to the labeling section.
5. The apparatus defined in claim 1, wherein the index member
includes multiple receiving compartments.
6. The apparatus defined in claim 5, wherein at least one receiving
compartment is of a different size than at least one other
receiving compartment in order to receive a vial of a different
size.
7. The apparatus defined in claim 1, wherein the receiving
compartment has a beveled upper edge.
8. The apparatus defined in claim 1, wherein the receiving
compartment has a chamfered side wall.
9. The apparatus defined in claim 1, wherein the receiving
compartment includes a side wall having a lagging edge portion, the
lagging edge portion including a stepped profile.
10. The apparatus defined in claim 1, wherein a lowermost edge of
the index member is raised above the base.
11. The apparatus defined in claim 1, wherein the labeling assembly
includes a drive roller and a pair of idler rollers, each of the
rollers being rotatable about a generally vertical axis of
rotation.
12. The apparatus defined in claim 11, wherein one of the idler
rollers is mounted on a shaft that is pivotally mounted to the
base, such that the roller is movable about a generally horizontal
axis of rotation.
13. The apparatus defined in claim 1, wherein the drive roller and
one idler roller are on opposite sides of a labeling gap through
which the labeling source presents the label.
14. The apparatus defined in claim 1, wherein the base further
comprises an exit guide that defines a path between the labeling
section and the pick-up section, and wherein the index member
contacts the vial and slides the vial from the labeling section to
the pick-up section along the exit guide.
15. An apparatus for applying a label to a pharmaceutical vial,
comprising: a base having a receiving section, a labeling section,
and a pick-up section; an index member attached to the base, the
index member including a receiving compartment, the index member
configured to receive a vial in the receiving compartment as the
receiving compartment is positioned over the receiving section and
convey the vial to the labeling section of the base; a label source
positioned to present a label to a vial located in the labeling
section of the base; and a labeling assembly mounted in the
labeling section of the base, the labeling assembly configured to
receive the vial from the index member and apply the label to the
vial; the index member being further configured to convey the
labeled vial from the labeling section to the pick-up section.
16. The apparatus defined in claim 15, wherein the index member is
rotatably mounted to the base.
17. The apparatus defined in claim 15, wherein the index member is
configured to contact the vial and slide the vial across the base
from the receiving section to the labeling section.
18. The apparatus defined in claim 15, wherein the index member
includes multiple receiving compartments.
19. The apparatus defined in claim 18, wherein at least one
receiving compartment is of a different size than at least one
other receiving compartment in order to receive a vial of a
different size.
20. The apparatus defined in claim 15, wherein the receiving
compartment has a beveled upper edge.
21. The apparatus defined in claim 15, wherein the receiving
compartment has a chamfered side wall.
22. The apparatus defined in claim 15, wherein the receiving
compartment includes a side wall having a lagging edge portion, the
lagging edge portion including a stepped profile.
23. The apparatus defined in claim 15, wherein a lowermost edge of
the index member is raised above the base.
24. The apparatus defined in claim 15, wherein the labeling
assembly includes a drive roller and a pair of idler rollers, each
of the rollers being rotatable about a generally vertical axis of
rotation.
25. The apparatus defined in claim 24, wherein one of the idler
rollers is mounted on a shaft that is pivotally mounted to the
base, such that the roller is movable about a generally horizontal
axis of rotation.
26. The apparatus defined in claim 15, wherein the drive roller and
one idler roller are on opposite sides of a labeling gap through
which the labeling source presents the label.
27. The apparatus defined in claim 15, wherein the base further
comprises an exit guide that defines a path between the labeling
section and the pick-up section, and wherein the index member
contacts the vial and slides the vial from the labeling section to
the pick-up section along the exit guide.
28. An apparatus for applying a label to a pharmaceutical vial,
comprising: a base having a labeling section and a pick-up section;
an index member attached to the base, the index member including a
receiving compartment; a label source positioned to present a label
to a vial located in the labeling section of the base; and a
labeling assembly mounted in the labeling section of the base, the
labeling assembly configured to receive the vial from the index
member and apply the label to the vial; the index member being
further configured to convey the labeled vial from the labeling
section to the pick-up section.
29. The apparatus defined in claim 28, wherein the index member and
base are configured such that the index member slides the vial
along the base from the labeling section to the pick-up
section.
30. The apparatus defined in claim 29, wherein the base further
comprises an exit guide that guides the vial as it slides from the
labeling section to the pick-up section.
31. The apparatus defined in claim 29, wherein the index member is
rotatably mounted to the base, such that rotation of the index
member defines an index member diameter, and wherein the pick-up
section is located outside of the index member diameter.
32. The apparatus defined in claim 28, wherein the receiving
compartment has a chamfered side wall.
33. The apparatus defined in claim 28, wherein the receiving
compartment includes a side wall having a lagging edge portion, the
lagging edge portion including a stepped profile.
34. The apparatus defined in claim 30, wherein a lowermost edge of
the index member is raised above the base, such that the index
member can pass over the exit guide.
35. A labeling assembly for use with a vial labeling apparatus,
comprising: a generally horizontal base; a drive roller unit
mounted to the base, the drive roller unit including a drive roller
that is rotatable relative to the base about a first generally
vertical axis of rotation and a drive unit that drives the drive
roller about the first axis of rotation; an idler roller unit
mounted to the base, the idler roller unit including an idler
roller that is rotatable relative to the base about a second
generally vertical axis of rotation; and a swing wheel unit mounted
to the base, the swing wheel unit including a shaft and a swing
wheel that is rotatable relative to the shaft about a third
generally vertical axis of rotation defined by the shaft, the shaft
being pivotally mounted in the base for rotation about a generally
horizontal axis of rotation, such that the position of the swing
wheel relative to the drive roller unit and the idler roller unit
can be modified to accommodate different sizes of pharmaceutical
vials for labeling.
36. The apparatus defined in claim 35, further comprising a
labeling source that presents a label to a vial as the vial engages
the drive roller, idler roller and swing wheel.
37. The apparatus defined in claim 36, wherein the drive roller and
the idler roller are on opposite sides of a labeling gap through
which the labeling source presents the label.
38. The apparatus defined in claim 35, wherein the swing wheel is
positioned at a lower elevation than the drive roller and the idler
roller.
39. The apparatus defined in claim 35, wherein the swing wheel is
mounted to the base at a position so that the shaft of the swing
wheel unit cants toward the vial as the swing wheel engages the
vial.
40. The apparatus defined in claim 35, wherein the swing wheel unit
further comprises a rotary solenoid that modifies the position of
the swing wheel.
41. A method of labeling a pharmaceutical vial, comprising the
steps of: receiving a pharmaceutical vial in a receiving section;
conveying the vial with an index member to a labeling section
adjacent a labeling source; applying a label presented by the
labeling source to the vial; conveying the labeled vial with the
index member away from the labeling section to a pick-up section;
and removing the labeled vial from the pick-up section.
42. The method defined in claim 41, wherein the receiving section,
the labeling section, and the pick-up section are located on a
common base.
43. The method defined in claim 41, wherein the index member is
rotatably mounted to a base, and wherein the conveying steps
comprise rotating the index member to convey the vial.
44. The method defined in claim 41, wherein applying a label
comprises rotating the vial as the labeling source presents an
adhesive label.
45. The method defined in claim 41, wherein the receiving step
further comprises the dispensing a vial from a vial dispenser into
the receiving compartment.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed generally to the
dispensing of prescriptions of pharmaceuticals, and more
specifically is directed to the automated dispensing of
pharmaceuticals.
BACKGROUND OF THE INVENTION
[0002] Pharmacy generally began with the compounding of medicines,
which entailed the actual mixing and preparing of medications.
Heretofore, pharmacy has been, to a great extent, a profession of
dispensing, that is, the pouring, counting, and labeling of a
prescription, and subsequently transferring the dispensed
medication to the patient. Because of the repetitiveness of many of
the pharmacist's tasks, automation of these tasks has been
desirable.
[0003] Some attempts have been made to automate the pharmacy
environment. Different exemplary approaches are shown in U.S. Pat.
No. 5,337,919 to Spaulding et al. and U.S. Pat. Nos. 6,006,946;
6,036,812 and 6,176,392 to Williams et al. The Williams system
conveys a bin with tablets to a counter and a vial to the counter.
The counter dispenses tablets to the vial. Once the tablets have
been dispensed, the system returns the bin to its original location
and conveys the vial to an output device. Tablets may be counted
and dispensed with any number of counting devices. Drawbacks to
these systems typically include the relatively low speed at which
prescriptions are filled and the absence in these systems of
securing a closure (i.e., a lid) on the container after it is
filled.
[0004] One additional automated system for dispensing
pharmaceuticals is described in some detail in U.S. Pat. No.
6,971,541 to Williams et al. This system has the capacity to select
an appropriate vial, label the vial, fill the vial with a desired
quantity of a selected pharmaceutical tablet, apply a cap to the
filled vial, and convey the labeled, filled, capped vial to an
offloading station for retrieval.
[0005] Although this particular system can provide automated
pharmaceutical dispensing, certain of the operations may be
improved. For example, the speed and precision with which labels
are applied to a vial may be improved. In particular, the Williams
et al. system relies on a first robotic arm to maneuver an empty
vial from a vial dispenser to a labeler, and a second robotic arm
to convey the empty labeled vial from the labeler to a bin that
dispenses pharmaceutical tablets. It may be desirable to eliminate
the first robotic arm in order to improve the speed and reliability
of the system.
SUMMARY OF THE INVENTION
[0006] As a first aspect, embodiments of the present invention are
directed to an apparatus for applying a label to a pharmaceutical
vial. The apparatus comprises: a base having a receiving section
and a labeling section; an index member attached to the base, the
index member including a receiving compartment, the index member
configured to receive a vial from a vial dispenser in the receiving
compartment as the receiving section is positioned over the
receiving section and convey the vial to the labeling section of
the base; a label source positioned to present a label to a vial
located in the labeling section of the base; and a labeling
assembly mounted in the labeling section of the base, the labeling
assembly configured to receive the vial from the index member and
rotate the vial as the label is presented to the vial to apply the
label to the vial. In this configuration, the same component can
both receive the vial from the vial dispenser and convey it to the
labeling assembly for application of the label.
[0007] As a second aspect, embodiments of the present invention are
directed to an apparatus for applying a label to a pharmaceutical
vial, comprising: a base having a receiving section, a labeling
section, and a pick-up section; an index member attached to the
base, the index member including a receiving compartment, the index
member configured to receive a vial from a vial dispenser in the
receiving compartment as the receiving section is positioned over
the receiving section and convey the vial to the labeling section
of the base; a label source positioned to present a label to a vial
located in the labeling section of the base; and a labeling
assembly mounted in the labeling section of the base, the labeling
assembly configured to receive the vial from the index member and
apply the label to the vial. The index member is further configured
to convey the labeled vial from the labeling section to the pick-up
section. In this configuration, a common index member can convey a
vial from a vial dispensing station to the labeler and subsequently
to a carrier for dispensing of pharmaceuticals.
[0008] As a third aspect, embodiments of the present invention are
directed to an apparatus for applying a label to a pharmaceutical
vial, comprising: a base having a labeling section and a pick-up
section; an index member attached to the base, the index member
including a receiving compartment; a label source positioned to
present a label to a vial located in the labeling section of the
base; and a labeling assembly mounted in the labeling section of
the base, the labeling assembly configured to receive the vial from
the index member and apply the label to the vial. The index member
is further configured to convey the labeled vial from the labeling
section to the pick-up section. In this configuration, a single
index member can convey a labeled vial from the labeling assembly
to a pick-up station for retrieval by a carrier that takes the
labeled vial to a pharmaceutical dispenser for dispensing.
[0009] As a fourth aspect, embodiments of the present invention are
directed to a labeling assembly for use with a vial labeling
apparatus. The labeling assembly includes: a generally horizontal
base; a drive roller unit mounted to the base, the drive roller
unit including a drive roller that is rotatable relative to the
base about a first generally vertical axis of rotation and a drive
unit that drives the drive roller about the first axis of rotation;
an idler roller unit mounted to the base, the idler roller unit
including an idler roller that is rotatable relative to the base
about a second generally vertical axis of rotation; and a swing
wheel unit mounted to the base. The swing wheel unit includes a
shaft and a swing wheel that is rotatable relative to the shaft
about a third generally vertical axis of rotation defined by the
shaft, the shaft being pivotally mounted in the base for rotation
about a generally horizontal axis of rotation, such that the
position of the swing wheel relative to the drive roller unit and
the idler roller unit can be modified to accommodate different
sizes of pharmaceutical vials for labeling.
[0010] As a fifth aspect, embodiments of the present invention are
directed to a method of labeling a pharmaceutical vial. The method
comprises the steps of: receiving a pharmaceutical vial from a
dispenser of pharmaceutical vials in a receiving section; conveying
the vial with an index member to a labeling section adjacent a
labeling source; applying a label presented by the labeling source
to the vial; conveying the labeled vial with the index member away
from the labeling section to a pick-up section; and removing the
labeled vial from the pick-up section. This method employs a common
index member to convey the vial from a vial dispenser to a labeling
station for labeling, then from the labeling station to a pick-up
location for retrieval by a carrier for subsequent filling with
pharmaceuticals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a flow chart illustrating an embodiment of a
method according to the present invention.
[0012] FIG. 2 is a front perspective view of a pharmaceutical
tablet dispensing system according to the present invention.
[0013] FIG. 3 is a rear cutaway perspective view of the system of
FIG. 2 illustrating the support frame, the container dispensing
station, the labeling station, the dispensing carrier, and the
closure dispensing station.
[0014] FIG. 4 is a front perspective view of a vial labeling
station according to embodiments of the present invention.
[0015] FIG. 5 is an enlarged perspective view of the index member
of the vial labeling station of FIG. 4.
[0016] FIG. 6 is a front view of the index member of FIG. 5.
[0017] FIG. 7 is a front perspective view of the vial labeling
station of FIG. 4 showing the index member moving a vial to the
labeling station.
[0018] FIG. 8 is a front perspective view of the labeling section
of the vial labeling station of FIG. 4 illustrating the swing
roller unit in the retracted position.
[0019] FIG. 9 is a front perspective view of the labeling section
of FIG. 8 illustrating the swing roller unit in the engaged
position.
[0020] FIG. 10 is a top view of the labeling section of the
labeling station of FIG. 8.
[0021] FIGS. 11 and 12 are top views of the labeling section of
FIG. 8 showing how vials of different sizes can be
accommodated.
[0022] FIG. 13 is a top view of the labeling section of FIG. 8
showing how the positions of the rollers influence the exit
direction of the vial.
[0023] FIG. 14 is a top view of the labeling and pick-up stations
of the vial labeling station of FIG. 4 showing the interaction
between the index member, a vial, and the exit guide.
[0024] FIG. 15 is a side perspective view of the pick-up station of
the vial labeling station of FIG. 4.
[0025] FIG. 16 is a top view of the pick-up station of FIG. 15
showing the relative positions of large and small diameter
vials.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0026] The present invention will now be described more fully
hereinafter, in which preferred embodiments of the invention are
shown. This invention may, however, be embodied in different forms
and should not be construed as limited to the embodiments set forth
herein. Rather, these embodiments are provided so that this
disclosure will be thorough and complete, and will fully convey the
scope of the invention to those skilled in the art. In the
drawings, like numbers refer to like elements throughout.
Thicknesses and dimensions of some components may be exaggerated
for clarity.
[0027] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and will not be
interpreted in an idealized or overly formal sense unless expressly
so defined herein.
[0028] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operations, elements, components, and/or groups thereof. As
used herein the expression "and/or" includes any and all
combinations of one or more of the associated listed items.
[0029] In addition, spatially relative terms, such as "under",
"below", "lower", "over", "upper" and the like, may be used herein
for ease of description to describe one element or feature's
relationship to another element(s) or feature(s) as illustrated in
the figures. It will be understood that the spatially relative
terms are intended to encompass different orientations of the
device in use or operation in addition to the orientation depicted
in the figures. For example, if the device in the figures is turned
over, elements described as "under" or "beneath" other elements or
features would then be oriented "over" the other elements or
features. Thus, the exemplary term "under" can encompass both an
orientation of over and under. The device may be otherwise oriented
(rotated 90 degrees or at other orientations) and the spatially
relative descriptors used herein interpreted accordingly.
[0030] Well-known functions or constructions may not be described
in detail for brevity and/or clarity.
[0031] As described above, the invention relates generally to a
system and process for dispensing pharmaceuticals. An exemplary
process is described generally with reference to FIG. 1. The
process begins with the identification of the proper container,
tablets or capsules and closure to be dispensed based on a
patient's prescription information (Box 20). A container of the
proper size is dispensed at a container dispensing station (Box
22), then is conveyed to a labeling station (Box 24). The labeling
station applies a label (Box 26), after which the container is
conveyed to a tablet dispensing station (Box 28), from which the
designated tablets are dispensed in the designated amount into the
container (Box 30). The filled container is then moved to a closure
dispensing station (Box 32), where a closure of the proper size has
been dispensed (Box 34). The filled container is secured with a
closure (Box 36), then transported to an offload station and
offloaded (Box 38).
[0032] A system that can carry out this process is illustrated in
FIGS. 2 and 3 and designated broadly therein at 40. The system 40
includes a support frame 44 for the mounting of its various
components. The system 40 generally includes as operative stations
a controller 42, a container dispensing station 58, a labeling
station 100, a tablet dispensing station 62, a closure station 64,
and an offloading station 66. In the illustrated embodiment,
containers, tablets and closures are moved between these stations
with a dispensing carrier 70; however, in some embodiments multiple
carriers may be employed. With the exception of the labeling
station 100, which is described in detail below, examples of each
of the other operative stations and the conveying devices are
described in detail in U.S. Pat. No. 6,971,541 to Williams et al.,
the disclosure of which is hereby incorporated herein in its
entirety, and/or in co-pending and co-assigned U.S. patent
application Ser. No. ______, filed concurrently, entitled DEVICE
FOR DISPENSING VIALS USEFUL IN SYSTEM AND METHOD FOR DISPENSING
PRESCRIPTIONS (Attorney Docket No. 9335-22).
[0033] Referring now to FIG. 4, the labeling station 100 is shown
therein. The labeling station 100 includes a base 102, an index
member assembly 110, and a labeling assembly 139. These components
are described in greater detail below.
[0034] Referring again to FIG. 4 and also to FIGS. 5 and 7, the
base 102 includes a base plate 106 supported from underneath by
legs 104. Typically, the base plate 106 is generally planar. In the
illustrated embodiment, the base plate 106 is slightly angled
relative to the underlying surface, with the labeling assembly 139
being on the higher end; an angle of between about 0.5 and 2.0
degrees is typical. A semicircular drop guide 107 is positioned on
one end of the upper surface of the base plate 106, with the center
of its arc located near the center of the base plate 106. A
receiving section 109 can be defined within the drop guide 107. An
exit guide 108 extends along a curved path from a point near the
center of the base plate 106 away from the drop guide 107 toward
the opposite end of the base plate 106. A pick-up section 111 is
located near the end of the exit guide 108. A labeling section 138
is positioned generally between the receiving section 109 and the
pick-up section 111, with the labeling assembly 139 being mounted
thereon.
[0035] Referring again to FIGS. 4 and 5, the index member assembly
110 includes an index motor 112 and an index member 116 (shown as
generally one half of a wheel). The index motor 112 is mounted to
the base plate 106 at or near the center thereof. A hexagonal shaft
114 extends upwardly from the motor 112. The index member 116
includes a top panel 118 that is generally horizontally disposed.
The underside of the top panel 118 includes a hexagonal recess (not
shown) that receives the shaft 114 of the index motor 112 and
causes the index member 116 to rotate with the shaft 114. The index
member 116 is attached to the shaft 114 via a locking device 115
positioned atop the top panel 118. Consequently, the index member
116 is rotatable relative to the base plate 106 about a generally
vertical axis A1 that passes through the shaft 114.
[0036] Referring again to FIGS. 4 and 5 and also to FIG. 6, the
index member 116 includes two receiving compartments: a large vial
compartment 120 and a small vial compartment 122. Each of the
compartments 120, 122 includes an upper beveled surface 124 that
merges with the top panel 118 and extends downwardly therefrom, a
chamfered surface 126 that merges with and extends downwardly from
the beveled surface 124, and a lower wall 128 that merges with and
extends downward from the chamfered surface 126; the result is a
generally conically-shaped wall that extends over an arc of
approximately 150 degrees and defines the radially inward wall of
the chambers 120, 122. Each of the compartments 120, 122 may be
sized to receive vials of a particular size range; for example, the
large vial compartment 120 may have a diameter of about 2 inches
and be particularly suitable for receiving vials having a diameter
of between 1.7 and 2.2 inches, and the small vial compartment 122
may have a diameter of about 1.5 inches and be particularly
suitable for receiving vials having a diameter of between 1.0 and
1.7 inches. The drop guide 107 described above provides the
radially outward wall of each of the chambers 120, 122.
[0037] Referring now to FIG. 6, a lagging edge portion 129 of the
chamfered surface 126 has a stepped profile 130, such that the
lower section thereof extends farther from the axis A1 than does
the upper section. The lowermost edge 132 of the lower wall 128 is
raised above the base plate 106 at a height sufficient to clear the
exit guide 108 when the index member 116 rotates. Also, each
compartment 120, 122 includes a cutout 134 that extends upwardly
from the lowermost edge 132.
[0038] Turning now to FIG. 8, the base plate 106 also includes a
labeling section 138, in which the application of labels to vials
occurs via the labeling assembly 139. The labeling assembly 139
includes a drive roller unit 140, an idler roller unit 146, and a
swing idler wheel unit 150 mounted in the labeling section 138.
These components are described in greater detail below.
[0039] The drive roller unit 140 (FIGS. 8 and 9) includes a motor
142 that is mounted to the base plate 106. A shaft 143 extends
upwardly from the motor 142 through an aperture in the base plate
106. A drive roller 144 is positioned on and fixed to the shaft 143
for rotation about a generally vertical axis of rotation A2 defined
by the shaft 143. The drive roller 144 is typically formed of a
polymeric material such as urethane, may have a diameter of between
about 0.5 and 1.0 inches, and is typically about 1.5 to 2.0 inches
in length (which length may correspond to the length of a label to
be applied to a vial).
[0040] Referring again to FIGS. 8 and 9, the idler roller unit 146
includes a shaft 147 that, in this embodiment, is mounted in the
base plate 106 nearer to the edge of the drop guide 107 than is the
drive roller unit 140. The idler roller unit 146 also includes an
idler roller 148 that is mounted to the shaft 147 and rotatable
relative thereto about a generally vertical axis of rotation A3
defined by the shaft 147. The idler roller 148 is typically between
about 0.25 and 0.5 inches in diameter, such that there is a label
gap 149 of between about 1 and 2 inches between the idler roller
148 and the drive roller 144.
[0041] The swing idler wheel unit 150 includes a shaft 152 and a
swing idler wheel 158 that rotates relative to the shaft 152 about
an axis of rotation A4 defined by the shaft 152. The shaft 152
extends through a slot 153 in the base plate 106 and is mounted in
the illustrated embodiment to a rotary solenoid 156 that is
mounted, in turn, to a bracket (not shown) fixed to the underside
of the base plate 106. The shaft 152 is pivotable via the rotary
solenoid 156 about a generally horizontal axis of rotation A5
defined by a pivot 154 on the solenoid 156 over a range of between
about 25 and 45 degrees, which in turn enables the wheel 158 to
move toward and away from the drive roller 144 and the idler roller
148 about 1 to 2 inches. The swing idler wheel 158 typically has a
diameter of between about 0.25 and 0.75 inches.
[0042] Because vials of different sizes may be presented to the
labeling assembly 139, the locations of the drive roller and idler
roller units 140, 146 and the swing idler wheel unit 150 may be
selected to handle different vial sizes. In the illustrated
embodiment, the label gap 149 is selected such that the smallest
vial to be presented cannot slip through the gap 149 (see vial V in
FIG. 11); typically, the gap 149 is between about 1 and 2 inches in
width. Also, in the illustrated embodiment the location of the
swing idler wheel unit 150 is selected so that the idler wheel 158
can contact a vial (a) at a height below that of the uppermost edge
of the drive roller 144, and (b) at an angle at which the shaft 152
and the idler wheel 158 are canted toward the vial, which tend to
apply a downward force on the vial to maintain it on the base plate
106 during subsequent rotation of the vial as described below.
Moreover, the position of the idler wheel unit 150 may be selected
to ensure that, for the largest vial to be presented to the
labeling assembly 139, the lines drawn between the contact points
of the rollers 144, 148 and the wheel 158 are on opposite sides of
the center of the vial so that the vial does not "squirt" away from
the rollers 144, 148 and the wheel 158 when the wheel 158 applies a
radially inward force (see vial V' in FIG. 12).
[0043] Referring now to FIG. 15, the pick-up area 111 includes the
exit guide 108 and the portion of the baseplate 106 adjacent
thereto. The exit guide 108 is routed from the labeling section 138
to the pick-up area 111, where the carrier 70 can retrieve a
labeled vial for subsequent filling and capping. In some
embodiments, the exit guide 108 is of sufficient length that it
extends beyond the diameter D defined by the rotating index member
116 (see FIGS. 7 and 16).
[0044] In operation, the labeling station 100 begins with the index
member 116 in the position shown in FIG. 4 (i.e., with the
compartments 120, 122 facing the drop guide 107) and the swing
idler wheel 158 in a retracted position such as that shown in FIG.
10. The controller 42 receives an order for a prescription and
signals a vial dispenser 190 (FIG. 4), such as that discussed in
application Ser. No. ______ (Attorney Docket No. 9335-22)
referenced above, to dispense a vial of a desired size. If a small
vial is desired (as is represented in FIG. 4 by the vial V), it is
deposited into the small vial compartment 122. Conversely, if a
large vial is desired, it would be deposited in the large vial
compartment 120. The ensuing discussion will focus on the
deposition of a small vial in the small vial compartment 122; those
skilled in this art will appreciate that the discussion is equally
applicable to the labeling and pick-up of a large vial also.
[0045] Notably, the presence of the beveled upper surface 124 in
the small vial compartment 122 encourages the vial V presented to
the compartment 122 to enter the compartment 122 (see FIG. 6). In
the illustrated embodiment, vials V are deposited in the large vial
compartment 122 with their open ends facing upwardly and their
closed ends on the surface of the base plate 106 within the large
vial compartment 122.
[0046] Once the vial V has entered the small vial compartment 122,
the controller 42 signals the index motor 112, which activates and
rotates the index member 116 about the axis A1 (counterclockwise
from the vantage point of FIG. 4). The controller 42 generates the
signal based on a predetermined duration after the vial V is
dropped by a mechanism within the vial dispenser 190;
alternatively, proximity or optic sensors or other detectors may be
employed. As the index member 116 rotates, the lagging edge portion
129 contacts the vial V and pushes it along the base plate 106 to
the labeling section 138 (see FIG. 6). Notably, the chamfered
surface 126 tapers away from the upper end of the vial V so that
any lip or other structure (such as a tamper-proof edge or the
like) does not contact the wall of the compartment 122; this
arrangement can facilitate smooth sliding of the vial V in a
stable, untipped condition when pushed by the index member 116.
[0047] Once the index member 116 pushes the vial V to the labeling
section 138, the index motor 112 ceases, thereby stopping the index
member 116. The cessation of rotation can be initiated by a sensor
in the labeling assembly 139, a timer, an encoder, or the like. In
this position, the cutout 134 is positioned in front of the swing
idler wheel shaft 152. Then, based on a duration lapse, a counter
in the motor 112, or the like, the controller 42 actuates the
rotary solenoid 156 to rotate the shaft 152 of the swing idler
wheel unit 150 about the axis A5 (counterclockwise from the vantage
point of FIG. 9) through the cutout 134 in the index member 116.
The shaft 152 rotates until the idler wheel 158 contacts the side
wall of the vial V, thereby forcing the vial V against the idler
roller 148 and the drive roller 144. This motion can be controlled
with a torque sensor, a position sensor, or the like. It may be
desirable for the swing idler wheel 158 to exert a force on the
vial V in order to consistently seat the vial V within the rollers
144, 148 and the wheel 158. The angle .alpha. formed by the shaft
152 relative to the base plate 106 is typically between about 25
and 45 degrees, which angle can force the vial downwardly during
application of a label.
[0048] After the vial V is engaged by the rollers 144, 148 and the
wheel 158, after a short predetermined duration the controller 42
signals the motor 142 of the drive roller unit 140 to rotate the
drive roller 144 about the axis A2 (rotation is clockwise from the
vantage point of FIG. 10). Also, the controller 42 signals a label
source, such as the illustrated label printer 200, to print and
present a label L (FIG. 10) for application to the vial V. In some
embodiments, it may be desirable to initiate rotation of the drive
roller 144 prior to the presentation of the label L, as rotation of
the vial V may allow a vial that is not seated flush on the base
plate 106 to adjust to a flush condition. In the illustrated
embodiment, the label L is presented into the label gap 149
adjacent the drive roller 144; in some embodiments, it may be
desirable to present the label L at an angle such that the leading
edge of the label L meets the vial V generally tangentially and/or
at the interface between the roller 144 and the vial V. The label L
has an adhesive applied to the surface thereof that faces the side
wall of the vial V and therefore adheres thereto. The rotation of
the drive roller 144 causes the vial V to rotate (counterclockwise
from the vantage point of FIG. 10), which rotation draws the label
L onto the side wall of the vial V. The label L passes through the
nip between the vial V and the drive roller 144 such that the label
L is smoothly applied to the rotating vial V. As the vial V
rotates, it is maintained in place by the idler roller 148 and the
swing idler wheel 158, each of which passively rotates as the vial
V is driven by the drive roller 144.
[0049] Once the label L has been completely applied to the vial V,
the controller 42, typically based on a predetermined elapsed time
period, signals the solenoid 156 to retract the swing idler wheel
158 back through the cutout 134. Shortly afterward, the controller
42 also signals the index motor 112 to rotate the index member 116
(counterclockwise from the vantage point of FIG. 13). The lagging
edge 129 of the small vial compartment 122 pushes the vial V
initially in a direction normal to the surface of the drive roller
44, which enables the vial V to reach and travel along a path
defined by the exit guide 108 to the pick-up area 111. Notably, the
stepped profile 130 of the lagging edge portion 129 of the
compartment 122 enables the lagging edge portion 129 to avoid the
lip of the vial V as it is being pushed along the exit guide 108.
The exit guide 108 extends beyond the reach of the index member 116
(i.e., outside the diameter D defined by the rotating index member
116), such that the vial V travels along the exit guide 108 a
sufficient distance to allow the index member 116 to rotate out of
the way prior to the entry of the carrier 70 into the pick-up area
111 to retrieve the labeled vial V.
[0050] Referring now to FIG. 16, it can be seen that vials of
different diameters (either a small vial V or a large vial V') can
each reach the end of the exit guide 108 for pick-up by the carrier
70.
[0051] Typically, the difference in location of the center of the
vial based on its diameter can be addressed by the controller 42,
which can alert the carrier 70 to the size of the vial so that the
carrier 70 travels to the appropriate location for pick-up.
[0052] Those skilled in this art will recognize that components
described above may be present in other forms in alternative
embodiments of the present invention. For example, the index member
assembly 110 may include an index member that revolves around a
non-circular endless path rather than rotating about a stationary
axis or that moves along a linear path. The compartments 120, 122
of the index member 116 may have a different profile for the inner
surfaces thereof; e.g., they may lack a beveled surface and/or a
chamfered surface, or they may be smoothly conical. The
compartments 120, 122 may be the same size. The index member may
have only one compartment or may have more than two compartments
(for example, it may have two compartments for large vials and two
for small vials). The index member 116 may counter-rotate after
depositing the labeled vial at the pick-up section 111 rather than
continuing to rotate in the same direction, or the index member 116
may be configured such that the carrier 70 can retrieve the labeled
vial without the index member 116 rotating out of the way. Further,
in some embodiments, separate members may be employed for (a)
conveying the vial from the point of vial dispensing to labeling
and (b) conveying the labeled vial to the pick-up section. Other
alternatives may be apparent to those skilled in this art.
[0053] In addition, the labeling assembly may be configured
differently in alternative embodiments. For example, there may be
multiple drive rollers, and/or more or fewer rollers. The label may
be presented to the vial at a different angle and/or at a different
location. The timing of various actions of the labeling assembly
may be different (e.g., the drive roller may cease rotation before
the index member 116 resumes its rotation after labeling occurs, or
the signaling of the solenoid to retract the swing idler wheel may
be based on parameters other than elapsed time). The swing wheel
shaft may be stationary relative to the base, particularly if it is
anticipated that only one vial size will be labeled, or may be
rotated via components other than a rotary solenoid, such as a
linear solenoid or a BTA actuator. Alternatively, the vial may be
rotated by a turntable positioned below the vial rather than by
rollers. The labels may be presented by a source other than a
printer (e.g., they could be presented manually). Those skilled in
this art will recognize other alternatives.
[0054] Further, pick-up of the labeled vial may vary in other
embodiments. For example, the shape or length of the exit guide 108
may vary. Also, in some embodiments the carrier 70 may pick up the
labeled vial from the labeling section if space permits. Other
alternatives may also be suitable for use with the present
invention.
[0055] In addition, although the labeling station 100 is
illustrated and described herein as part of an overall
pharmaceutical dispensing system, those skilled in this art will
appreciate that the labeling station 100 may be employed as a
stand-alone device, perhaps mounted on a bench-top, for labeling
vials. Such a system may receive manually-fed vials and/or rely on
manual pick-up.
[0056] The foregoing is illustrative of the present invention and
is not to be construed as limiting thereof. Although exemplary
embodiments of this invention have been described, those skilled in
the art will readily appreciate that many modifications are
possible in the exemplary embodiments without materially departing
from the novel teachings and advantages of this invention.
Accordingly, all such modifications are intended to be included
within the scope of this invention as defined in the claims. The
invention is defined by the following claims, with equivalents of
the claims to be included therein.
* * * * *