U.S. patent application number 11/719370 was filed with the patent office on 2010-04-15 for apparatus for storing and dispensing packages.
Invention is credited to Jean-Louis Connier, Luc Hasenfratz, Rupert Katritzky, Guillaume Nogues.
Application Number | 20100089941 11/719370 |
Document ID | / |
Family ID | 35501186 |
Filed Date | 2010-04-15 |
United States Patent
Application |
20100089941 |
Kind Code |
A1 |
Connier; Jean-Louis ; et
al. |
April 15, 2010 |
APPARATUS FOR STORING AND DISPENSING PACKAGES
Abstract
An apparatus for storing and dispensing a plurality of packages
(28) comprises a first region (2) having a plurality of shelves (4)
accessible by a storage and picking device (6) and a second region
(12) having a plurality of channels (24), each for receiving a
plurality of packages (28) and each of which comprises independent
ejection means. The storage and picking device (6) is adapted to be
able to fill the channels (24) in the second region (12). The
apparatus further comprises conveying means (30) associated with
the second region for removing packages (28) ejected from the
second region (12).
Inventors: |
Connier; Jean-Louis; (La
Fleche, FR) ; Nogues; Guillaume; (Mareil Sur Loire,
FR) ; Katritzky; Rupert; (Monaco, MC) ;
Hasenfratz; Luc; (Hempstead, GB) |
Correspondence
Address: |
BLAKELY SOKOLOFF TAYLOR & ZAFMAN LLP
1279 OAKMEAD PARKWAY
SUNNYVALE
CA
94085-4040
US
|
Family ID: |
35501186 |
Appl. No.: |
11/719370 |
Filed: |
November 15, 2005 |
PCT Filed: |
November 15, 2005 |
PCT NO: |
PCT/GB05/04384 |
371 Date: |
June 8, 2009 |
Current U.S.
Class: |
221/123 |
Current CPC
Class: |
B65G 1/1376 20130101;
G16H 20/13 20180101; G06Q 10/08 20130101; B65G 1/08 20130101 |
Class at
Publication: |
221/123 |
International
Class: |
B65D 83/00 20060101
B65D083/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 15, 2004 |
GB |
0425142.7 |
Mar 16, 2005 |
GB |
0505395.4 |
Claims
1. An apparatus for storing and dispensing a plurality of packages
comprising a first region having a plurality of shelves accessible
by a storage and picking device and a second region having a
plurality of channels, each for receiving a plurality of packages
and each of which comprises independent ejection means, wherein the
storage and picking device is adapted to be able to fill the
channels in the second region; the apparatus further comprising
conveying means associated with the second region for removing
packages ejected from the second region.
2-53. (canceled)
Description
[0001] This invention relates to apparatus for the automated
storage and retrieval of small packages, particularly although not
exclusively pharmaceutical packages.
[0002] Automated pharmacies, whereby pharmaceuticals and the like
are stored, retrieved and dispensed without the need for human
intervention after the initial request, are well known in the art.
Typically such systems comprise a robot arm in communication with a
database of the locations of the packages on a rack of shelving.
When a request for a particular package is received, the robot arm
moves to the correct location, retrieves the desired package and
transfers it to a dispensing chute.
[0003] The maximum output rate of such systems is limited by the
speed with which the robot arm can move and the sweep area of the
arm--i.e. the area which the arm is required to cover. Clearly, the
output rate may be increased by providing a second or further robot
arms but this adds significantly to the cost and also adds to the
complexity of the system as they must be co-coordinated to avoid
obstructing one another.
[0004] Shelf space tends to be allocated dynamically in such
arrangements as packages are put into the system, so that there is
no correlation between the type of drug in the package and its
location on the shelving. Consequently, there is no correlation
between the type of drug and the time taken for it to be retrieved
and dispensed.
[0005] There is a recognition in the art that some types and sizes
of pharmaceutical packages are required much more often than
others. These are known in the art as "fast movers". In one
proposal disclosed in WO 03/010073, separate areas of shelving are
provided for fast movers each with its own dedicated robot arm on
the other side of the shelf for retrieving packages solely from
that area to allow fast movers to be retrieved more quickly without
interfering with the main robot arm.
[0006] However, the Applicant has appreciated that there are some
significant limitations associated with this arrangement. Firstly,
retrieval is still carried out by a robot arm which must be
translated in two-dimensions to the appropriate point on the shelf
to pick the pack before it can be dispensed and thus, although
quicker than the conventional arrangement, dispensing times are
still of the same order.
[0007] Secondly, the additional robot arms add significantly to the
expense as mentioned above. Furthermore this extra expense is
incurred for each module which is added as a particular
installation is expanded.
[0008] It is an object of the present invention to improve upon
such arrangements. When viewed from a first aspect the present
invention provides an apparatus for storing and dispensing a
plurality of packages comprising a first region having a plurality
of shelves accessible by a storage and picking device and a second
region having a plurality of channels, each for receiving a
plurality of packages and each of which comprises independent
ejection means, wherein the storage and picking device is adapted
to be able to fill the channels in the second region; the apparatus
further comprising conveying means associated with the second
region for removing packages ejected from the second region.
[0009] Typically, each channel comprises an independent ejection
mechanism.
[0010] Thus it will be seen by those skilled in the art that in
accordance with the invention a storage and dispensing system is
provided in which the second storage region does not rely on a
further robot arm but rather each channel of the second region can
output independently to the conveyor. This allows extremely rapid,
parallel output of packages. Furthermore, it is easily scalable
since the second, channel region can easily be produced in modular
form, e.g. with a common conveyor or with each module having a
conveyor for moving packages to the edge of the module and then
either to the conveyor of an adjacent module or to a downstream
dispensing system such as a further conveyor or dispensing
chute.
[0011] The Applicant has also appreciated that the arrangement of a
conveyor to receive packs ejected from the channel region means
that the conveying means may act as a kind of temporary buffer to
receive a plurality of different packs which are required together,
e.g. as a single prescription or to meet an order for a ward round.
By collecting the packages together before then conveying them
together to the delivery system or location, a significant time
saving is made over prior art arrangements in which each pack is
conveyed individually in turn to the delivery point. This is of
course of particular significance where there is a relatively long
separation between the storage and retrieval apparatus and the
ultimate destination--e.g. a pharmacy front counter. This will
normally be desirable so as to free up working space for pharmacy
personnel and to isolate the noise of the apparatus as it
operates.
[0012] If the apparatus of the invention is arranged at a
sufficiently elevated height, even after packages have been ejected
and have fallen from the channels of the channel region to end up
on the conveyor, they will still be at a sufficient height for the
final delivery mechanism e.g. a chute. In preferred embodiments,
however, lifting means are provided for lifting packages ejected
from the channel region and onto the conveyor to an increased
height. For example, in preferred embodiments the lifting means is
provided adjacent to the channel region and is arranged so that
packages ejected from the channels are conveyed to the lifting
means by the conveying means. This again is advantageous over the
arrangement with one or more robot arms for retrieval since it
enhances the flexibility of how the apparatus may be configured and
where it may be placed for delivery to a final delivery point, but
without significantly increasing the cost.
[0013] Furthermore, a single lift may be provided to serve a
plurality of channel modules; indeed further channel modules may be
added to an existing system without necessarily the need to add a
further lift. It has also been appreciated that the lifting means
may act as a buffer too, in addition to or instead of the conveying
means, to allow several packages to be collected and delivered
together which represents an enhancement in output speed as
compared to delivering the packages to the final delivery point one
at a time.
[0014] The lift is preferably arranged to eject the packages
thereon to a final delivery system such as a chute. Indeed, it is
envisaged that in some embodiments where it would be desirable to
have a number of different final delivery points--e.g. to serve a
plurality of operators--the lift could transport the packages to
one of a plurality of final delivery mechanisms. For example,
dispensing chutes could be arranged at different heights along the
travel of the lifting means so that the packages on the lifting
means may be selectively dispensed to a desired final delivery
point by raising them to the appropriate level to eject them.
[0015] The lifting means should be arranged so as to raise packages
to a different height and either deliver them to a further delivery
system such as an output chute or present them for retrieval. Many
designs are possible. One possibility is to arrange for the
conveying means, or at least part thereof, to be able to be raised
and lowered as required. This has some advantages including space
efficiency. Alternatively, a simple raised platform could be
provided.
[0016] Ejection of packs at the desired height can also be effected
in a number of ways. The raising platform could be inclined away
from the desired exit side of the lift with a door or gate attached
to the platform itself or on a wall of the apparatus facing the
platform. Alternatively the platform could be tilted only when the
destination height is reached, with or without a door/gate etc. In
one possible embodiment the platform is suspended from two opposite
sides so that tilting can be induced by differences in the height
of suspension between the two sides.
[0017] In accordance with the invention, the output from the first
region using the storage and retrieval device may be entirely
independent of the output from the second, channel region. However,
in at least some preferred embodiments there is at least some
overlap in the paths taken by packages dispensed from the first and
second regions respectively. Indeed, a common conveying means may
be used from which packages from both regions are conveyed to a
final delivery point. This might be helpful in realising the
benefits of the buffer function of the conveyor since the packages
required to make up a single order may be distributed between the
first and second regions. However, in preferred arrangements, the
packs dispensed from the first and second regions are separate from
one another for at least part of their paths since this helps to
avoid problems with bottle necks occurring and thereby slowing the
overall output rate.
[0018] Apparatus in accordance with the invention could be arranged
so that packages ejected from the channel region fall directly onto
the conveying means. This is, however, not preferred since it gives
rise to the possibility of damage being caused to the package or
its contents as a result of the force of the fall. In preferred
embodiments, therefore, a soft region for receiving falling
packages is provided from which the packages can fall or slide a
further short distance slide onto the conveyor. Many ways of
implementing this are possible although it is presently preferred
to provide a loosely-slung sheet of material--e.g. fabric that can
cushion the falling package without too great a tendency for
packages to bounce off.
[0019] In some preferred embodiments two distinct channel regions
may be provided, which could have a common soft landing area or
preferably individual ones, but feeding a common conveying
means.
[0020] The provision of two or more discrete channel regions is a
general feature of a set of preferred embodiments. Of course, in
accordance with the invention one of these channel regions will be
the second, channel region of the apparatus of the invention
referred to above. It will therefore be arranged so as to be filled
by the storage and retrieval device serving the first region of
shelving. Any additional channel regions could be served for
filling by the same device. Alternatively, one or more additional
storage and retrieval devices could be provided; or one or more of
the further channel regions may be arranged to be filled manually.
This would allow a manual backup in the event of malfunctioning of
the other channel region and/or allow the inputting of packages
into the system to be supplemented manually in order to speed up
input.
[0021] Where a plurality of channel regions is provided, these are
preferably served by a common lifting means although for reasons of
capacity or backup, more than one lift may be provided each of
which is able to serve each of the channel regions.
[0022] The ejection means associated with the individual channels
may take any convenient particular form, for example, the foremost
region of each channel could be arranged to tip or release the
package in that region out of the front of the channel whilst
preventing the other packages from being released; and thereafter
allowing the remaining packages to slide down the channel so that a
new package is received in the foremost region.
[0023] In a particularly preferred set of embodiments the ejection
means comprises a pivoting member arranged to pivot from a first
position in which it receives a package to a second position in
which it ejects the package, wherein said member is arranged so as
to be unable to receive a further package in said second
position.
[0024] Such an arrangement is considered to be novel and inventive
in its own right and thus when viewed from a further aspect the
invention provides a channel for receiving a plurality of packages
and ejection means for ejecting packages one at a time from the
channel, said ejection means comprising a pivoting member arranged
to pivot from a first position in which it receives a package to a
second position in which it ejects the package, wherein said member
is arranged so as to be unable to receive a further package in said
second position.
[0025] This is beneficial as it allows, simply and reliably, the
ejection of just one package at a time without the need for
complicated arrangements involving synchronised actuators or
actuators operating for precisely defined times.
[0026] In accordance with the aspect of the invention set out above
the remaining packs will be arranged so that another is received by
the pivoting member when one has been ejected and the member is
returned to its first position. This could be under any convenient
force such as a spring but preferably the channel is inclined so
that gravity causes the packs to move along the channel; towards
the pivoting member.
[0027] The pivoting member could be arranged to prevent packages
being received thereby additionally in the first position. This
would require a third position in which the pivoting member was
charged with the package which would then be `cradled` from both
sides. Preferably however the pivoting member is arranged to be
able to receive a package in the first position.
[0028] The pivoting member preferably comprises a front and rear
arms arranged such that in the first position the front arm
prevents ejection of the pack and in the second position the front
arm is retracted sufficiently for the pack to be ejected. The
second arm could then, preferably, be retracted in the first
position. It will be appreciated that the resulting arrangement is
somewhat analogous to an escapement mechanism.
[0029] The ejection means could be operated by any suitable
operating arrangement such as a motor, electromagnet, solenoid etc.
However the Applicant has devised a particularly convenient and
simple arrangement. In accordance with preferred embodiments the
ejection means is operated by thermally responsive actuating means,
means being provided to heat the thermally responsive actuating
means to cause it to adopt a different configuration thereby moving
the ejection means. The thermally responsive actuating means could
comprise a construction where the requisite movement is derived
from simple expansion, e.g. a bimetallic element. Preferably though
it comprises a shape memory material. Such materials are well known
per se and share the characteristic that they adopt a previously
formed shape when heated to a predetermined temperature. Although
some plastics exhibit this phenomenon it is preferred in the
present case to use a shape memory metal. Conveniently the heating
means comprises means for passing an electric current through at
least a part of the shape memory metal element itself so that the
element self-heats.
[0030] The ejection means, e.g. the preferred pivoting member,
could be arranged to return to a standby position under gravity or
could be actively moved to such a position but preferably it is
resiliently biased towards its standby position. In the preferred
embodiment comprising a pivoting member, the standby position
translates to the first position.
[0031] It will also be appreciated that the above-described channel
ejection means are preferred embodiments of the first aspect of the
invention set out previously.
[0032] In another alternative method of ejection, pressure may be
applied to a stack of packages in a channel from the rear end, that
is to say the end from which they are filled, in order to overcome
a retaining force of some sort and allow the foremost package to be
ejected. One advantage envisaged with this arrangement is that in
the event of malfunction, the storage and retrieval device might be
adapted to be able to apply the necessary pressure to a given
channel to eject a package therefrom. This would allow the
apparatus to continue to operate, albeit at a reduced output rate,
if such a malfunction were to occur.
[0033] Although not essential, it is generally preferred for the
channels in the channel region of the invention to slope towards
the front to assist ejection of packages therefrom. The Applicants
have appreciated that this creates an unused space at the bottom
rear of the channel region and in another preferred feature,
therefore the invention comprises providing shelving of the type
employed in the first region of the apparatus in the lower rear
part of the second, channel region. The advantage this brings in
enhancing compactness could be significant in small installations.
It should be appreciated that this is a further distinction over
arrangements of the sort disclosed in WO 03/010073 in which the
channel regions are provided as separate modules which are merely
placed adjacent to more traditional shelving.
[0034] An alternative use of this dead space would be to provide
the conveying means and thus in at least some preferred
embodiments, the conveying means of the invention is provided
directly beneath the channel region. In another alternative, the
dead space may be used to provide a dispensing chute to deliver
packages to a final delivery point.
[0035] A yet further and preferred use of the dead space is to
house an output chute for the first region of shelving. Especially
conveniently the output chute may be arranged to deliver packages
onto the conveying means of the channel region. This would allow
the advantages discussed above relating to the conveying and/or
lift means as a buffer to be extended to the whole of the shelving.
The output chute could be instead of a main output chute for the
first shelving region, but preferably it is in addition. Indeed
more generally it is preferred to provide a plurality of possible
outputs for the first region of shelving. This is advantageous as
it minimises the average distance the storage and retrieval device
must move and therefore increases its speed of operation.
[0036] It will be appreciated from the foregoing that in accordance
with the invention a storage and retrieval device is used to fill
the channels of a channel region for allowing the same packages to
be output rapidly.
[0037] The robot arms of conventional automated pharmacies are
controlled by a computer which maintains a database of the
locations of each package on the shelving. The channel region of
the invention could simply be incorporated into a system like this
so that the central database keeps a record of those packages which
are stored from and subsequently dispensed from the channel region.
However, this does potentially bring with it some complications.
For example, in ordinary shelving there is generally only one pack
at each location, whereas in the channel system there will be
normally be a plurality of packages in each channel; this could
cause difficulties in controlling software. Similarly the channel
will normally be a FIFO (first in; first out) system which the
controlling software may not easily be able to cater for. Thirdly,
by the nature of fast movers stored in the channel region, it is
especially disadvantageous to require frequent interrogation of the
main database.
[0038] According to some preferred embodiments therefore the
apparatus comprises communication means adapted to allow
communication between the storage and retrieval device and the
individuals channels or groups thereof. Suitable means include
radio, microwave, ultrasonic or visual light or, preferably,
infra-red transmission. The actual information communicated may be
adapted to suit the particular implementation but could include
identifying information about a package being put into a channel,
the number and/or type of packages held in a given channel, error
codes etc. Thus such communication might allow stock level control
at least for fast movers to be managed locally--i.e. remotely from
the central database. For example where a package of a given type
is stored in both the first and second regions it could allow a
decision as to the region in which to store a newly entered
package.
[0039] Such arrangements are novel and inventive in their own right
and thus when viewed from a further aspect the invention provides
apparatus for storing and dispensing a plurality of packages
comprising a plurality of discrete storage regions and filling
means for putting packages in said storage regions, the apparatus
further comprising means for communicating information between the
filling means and each storage region. The storage regions are
preferably channels.
[0040] The channel could pass information to the storage and
retrieval device as to its stock level e.g. to direct the latter to
place a package in a different channel if it is full. Indeed each
channel could have a memory to allow it to keep its own
mini-inventory and to request replenishment by the storage and
retrieval when its items have been dispensed from the channel. In
some preferred embodiments each channel has its own power supply
such as a battery.
[0041] Another advantageous feature which the Applicant has devised
and which may be used as appropriate comprises providing indicating
means on each of the channels in the channel region so as to be
visible to a user operating the apparatus manually in the event of
a breakdown. In a convenient example of this feature a simple light
could be lit for each of the channels from which a package must be
picked to fulfill a given order. Alternatively a display such as a
liquid crystal display (LCD) could be provided. This means that
even if the ejection system of the channel region were to stop
functioning, orders can still be fulfilled quickly by hand as a
user is told from which channels to pick and does not need to be
able to see the actual contents of the channels. Of course more
complicated information could be conveyed to a user by such visual
means, for example operational errors, stock required, mismatches
between actual and planned numbers of packs, low stock levels etc.
In one non-limiting example a pair of LEDs, e.g. red and green are
provided through which several messages may be conveyed depending
on the illumination or rate of flashing of the two LEDs.
[0042] The channels in the channel region will normally be arranged
so as to dispense packages automatically at the front upon receipt
of an appropriate command. Preferably each is further provided with
means for allowing manual ejection e.g. in the event of a
malfunction. This could be associated with the normal dispensing
mechanism and also allow removal of packages at the front of the
channel but the Applicant has realised that it is beneficial to
provide means for allowing manual removal of the packages in a
channel from the rear of the channel. This means that user access
to the space in front of the channel region, which is usually kept
small for optimising the use of space, is not required. There will
usually be more space at the rear of the channel region since space
is needed there to allow the storage and retrieval device to
operate.
[0043] The channels in the channel region may have fixed
dimensions. These need not all be the same and the distribution of
channel dimensions can be chosen to fit the normal distribution of
package sizes. However in some preferred embodiments at least some
of the channels have at least one variable dimension. In preferred
examples, the width of the channels is variable. This allows huge
flexibility for the contents of a given channel to be changed
depending upon prevailing requirements. The adjustment to the
channel dimension could be one carried out manually e.g. with
display means on each channel indicating that an adjustment is
required and possibly also the nature of the adjustment; but
preferably means are provided for altering the channel
automatically. For example a small servo motor could be provided to
effect the adjustment. This has the advantage of allowing frequent
adjustments so that the contents of a given channel can be assigned
dynamically.
[0044] Control of channel adjustments could be directed from a
central computer but equally could be controlled by communication
between the storage and delivery device and the channel itself as
is described above. For example the storage and retrieval device
could pass information as to the size of package it is holding to
the channel to allow the channel to adjust its size
accordingly.
[0045] One advantageous use of the apparatus of the preferred
embodiments of the invention is to use some or all of the channels
as a temporary hold for particular orders such as whole
prescriptions which are required together. Prescription orders are
often given with a reasonable degree of advance notice either
because they are regular repeats or because a customer intends to
return to collect them. This means that the whole prescription can
be made up, stored in one or more of the channels and dispensed
substantially simultaneously. Such a use particularly benefits from
the preferred automatic adjustment of channel dimensions since the
types of packages which are stored in channels used for this
purpose will change rapidly.
[0046] In conventional automated pharmacies it is normal for the
single robot arm to be controlled by a single microcomputer such as
a personal computer (PC). As installations get larger and are
operated by more personnel this creates a bottleneck. According to
a further aspect of the invention there is provided a computer
system for operating an automated pharmacy comprising a database
recording the physical positions of a plurality of packages and a
central module for processing orders for packages, the computer
system comprising a plurality of user interface modules each
adapted to interact with the order processing module to allow
orders to be uploaded and the status of said orders to be
monitored.
[0047] Thus in accordance with this module a plurality of operators
may use the system simultaneously with a central module processing
orders and allowing the individual operators to see the status of
their orders and preferably all the orders being processed. This
allows significantly more efficient working for a given
installation compared with the conventional unitary system. The
order processing module could be programmed with algorithms to
allow even more efficient operation. For example where, as is
preferred, the automated pharmacy comprises a channel region in
accordance with the first aspect of the invention the central
module may allocate orders between the storage and retrieval device
and the channels taking into account other orders it has
received.
[0048] Certain preferred embodiments of the invention will now be
described, by way of example only, with reference to the
accompanying drawings in which:
[0049] FIG. 1 is a schematic view of a first shelving region of an
embodiment of the invention;
[0050] FIG. 2 is a schematic diagram showing a second channel
region for use with the embodiment of FIG. 1;
[0051] FIG. 3 is a perspective view of an adjustable channel for
use with the invention;
[0052] FIG. 4 is a view of the channel of FIG. 3 rotated
180.degree.;
[0053] FIG. 5 is a view of the channel of FIGS. 3 and 4 with
enlarged detail showing the operating mechanism;
[0054] FIG. 6 is a schematic view of the channel region of a second
embodiment of the invention;
[0055] FIG. 7 shows the channel region of FIG. 6 in situ;
[0056] FIG. 8 is a schematic view of another embodiment of the
invention;
[0057] FIG. 9 is a sectional view through one embodiment of a
lifting arrangement;
[0058] FIG. 10 is a sectional view through another embodiment of a
lifting device;
[0059] FIG. 11 is a schematic view of another embodiment of a
lifting device;
[0060] FIG. 12 is a view of part of the lifting device of FIG.
11;
[0061] FIG. 13 is a sectional through yet another embodiment of a
lifting device;
[0062] FIGS. 14-19 are schematic views of various pharmacy layouts
which may be used in accordance with the invention;
[0063] FIG. 20 is a schematic view of a further embodiment of a
channel;
[0064] FIG. 21a is a schematic sectional view of the an ejector
mechanism of the channel of FIG. 20 in a standby mode; and
[0065] FIG. 21b is a view similar to FIG. 21a showing an ejection
mode.
[0066] The embodiments of the invention described herein below are
all automated pharmacy systems of the type generally known in the
art for storing large numbers of pharmaceutical packages and
dispensing them on demand in response to an order. The dimensions
and other physical characteristics of the various elements to be
described are therefore to be inferred from this use.
[0067] FIG. 1 shows a first, generally conventional region of
shelving designated generally by the reference numeral 2 and
comprising a vertically spaced array of elongate shelves 4 facing
inwardly on either side of a corridor. A conveyor belt 5 is
provided onto which packages are placed when they are received into
the pharmacy and from which they may be picked up and placed onto
the shelves 4. This runs the length of the shelving region 2 so
that a large number of packages can be input into the system at
once and thereafter placed onto the shelves 4 when the system is
not occupied fulfilling orders for dispensing. Although shown
transparent for reasons of clarity in this Figure, the shelves 4
and side walls of the corridor onto which the shelves back are
normally closed at least sufficiently to prevent the packages
passing through.
[0068] A robot arm assembly 6 is provided between the two sets of
shelves 4 on either side of the aisle. The arm 6 is mounted to a
vertical beam 8 on a sliding carriage that can be translated up and
down the vertical beam 8 and horizontally towards and away from the
shelves 4. The vertical beam 8 is itself mounted for translational
sliding movement on a pair of horizontally extending guide rails
10. The arrangement therefore allows the robot arm 6 to move freely
in the x, y or z direction. Furthermore the mounting of the arm
assembly 6 onto the vertical beam 8 is such as to permit a 180
degree rotational movement so that shelves 4 on both sides can be
accessed. The arm assembly 6 can therefore access any part of the
shelving region 2. Although not shown in the Figures, as is well
known in the art the arm assembly 6 comprises a pair of jaws which
may be opened and closed and raised and lowered to allow packages
to be manipulated. The robot arm 6 is depicted only schematically
in this Figure although in practice it may be any of the type
generally known in the art which are able to retrieve packages of a
variety of sizes, shapes and weights from these shelves 4 move them
to a different position and thereafter release them.
[0069] It will be observed that in FIG. 1 part of the foremost side
wall is left free of conventional shelves 4. Instead, in accordance
with the present invention this area is provided with a second,
channel region for frequently required packages otherwise known as
"fast movers". Some elements of the channel region are shown
schematically in FIG. 2.
[0070] Turning therefore to FIG. 2, it will be seen that the
channel region, designated by the numeral 12 generally comprises an
outer frame 14 which defines a front section 16 and a rear section
18 which is somewhat deeper than the front section 16 but of the
same width.
[0071] The frame 14 comprises three pairs of parallel vertical
struts, 14a, 14b and 14c at the rear, middle and front
respectively. A series of horizontal cross members 20 extend
between the rearmost vertical struts 14a. Similar horizontal cross
members 22 extend between the centre vertical struts 14b.
[0072] A series of adjacent channel structures 24 extend between
one of the rear cross members 20 and one of the essential cross
members 22. The central cross member 22 supporting the channel
structures 24 is lower than the corresponding rear cross member 20
so that the channel structures 24 slope downwardly from rear to
front e.g. at an angle of about 30.degree.. Only one layer of
channels 24 is shown in FIG. 2 for clarity but in practice there
will be a number of parallel layers at different heights. In
practice therefore a large proportion of the volume of the rear
section 18 of the frame will be filled with the array of parallel
channels 24.
[0073] The lower, front end of the channels 24 open into the front
part 16 of the channel region 12. The front part 16 is generally
open but towards the bottom there is a soft landing platform 26
which could for example consist of a piece of fabric stretched
across the frame, in order to cushion the fall of packages 28 which
fall from the channels 24. The soft platform 26 is angled
downwardly in a rearward direction so that packages 28 gently fall
off it onto a conveyor belt which is provided at the bottom of the
rear part 18 of the module, directly beneath the layers of channels
24. The conveyor 30 is operable in either lateral direction to
enable a package 28 to be conveyed either to the left or right edge
of the module 12.
[0074] The front vertical struts 14c are provided with an infrared
transmitter and receiver pair 32, 34 just above the soft landing
platform 26 which transmit and receive signals to and from the
individual channel assemblies 24 as will be explained in greater
detail below. To the rear of the conveyor 30 is an inclined chute
surface 36, the purpose of which will be explained below, and a
some further shelves 38. It will be appreciated therefore that
rather than the lower rear space, i.e. that which is left by the
slope of the channels 24, being wasted; the space is usefully used
by accommodating the additional output chute 36 and additional
shelving capacity 38.
[0075] Although shown separated, in practice the channel module 12
in FIG. 2 is positioned in the space in the shelving region 2
mentioned above. Further channel modules may be placed adjacent to
it depending on requirements.
[0076] FIGS. 3, 4 and 5 show one possible detailed configuration of
one of the channel assemblies 24. FIGS. 3 and 4 are views from the
front and rear of the channel respectively and are foreshortened to
allow all of the salient features to be easily seen. Each channel
24 comprises an elongate base member 40 which is fixed to the front
and rear cross members 20, 22. The base member 40 supports a pair
of L-shaped side wall members 42. Each side wall member 42 has two
horizontally extending arms 44 which, as is seen in the enlarged
portion of FIG. 5, have toothed edges 46 which engage cogs 48 to
allow the arms 44 to be translated horizontally in opposite
directions in a double rack and pinion drive arrangement as shown
in FIG. 5. This allows the two side walls 42 to be easily moved
together and apart to alter the width of the channel which allows
it to accommodate differently sized packages. The walls could be
adjusted manually by an operator (i.e. a service engineer would not
be required) or they could be moved by the robot arm 6. In another
possible embodiment (not shown) the cogs 48 could be replaced by
servo motors to allow the channels to be adjusted
automatically.
[0077] Towards the front of the channel 24 is a raised wire pack
stop 50 which prevents the packages sliding off the front end of
the channel. Immediately behind the pack stop 50 is an ejector flap
52 which is operable to flip up and push a package lying on it over
the pack stop thereby causing the package to slide off the front
end of the channel.
[0078] Immediately behind the ejector 52 is a pack detector 54
which is able to sense when there is a package at the front of the
channel behind the pack stop. A similar detector 56 is provided at
the very front of the channel in order to allow passing of a
dispensed package to be detected. A third pack detector 58 is at
the rear of the channel to allow the detection of newly entered
packages at the back of the channel.
[0079] Also at the back of the channel is a manual ejection button
60 which operates the ejector 52 when pressed by a user; and a
mechanical ejection lever 62 which enables the ejector 52 to be
operated by hand in the event of a power failure. The manual knobs
60, 62 therefore allow a user to eject a package from the normal,
front end of the channel in the event of various types of
malfunction. As will be appreciated by returning to FIG. 1, being
able to operate the manual ejection mechanisms from the rear of the
channel is beneficial since it avoids the need to provide user
access to the front of the apparatus. There is a reasonable amount
of space behind the channel module 12 when installed as this is
required for the robot arm 6 to operate.
[0080] Turning back to FIG. 3 on the front face of the channel
assembly 24 there is a light emitting diode (LED) 64 which is used
to indicate to a user in the event of a malfunction of the
apparatus that a package should be picked from that particular
channel in order to fulfill a given order. Next to the display LED
64 is an infrared emitter and receiver 66 which is the means by
which the channel assembly 24 communicates with the central
computer in normal use for receiving ejection commands and for
returning status information.
[0081] An infrared emitter and receiver 68 is provided on the rear
end of the channel assembly 24 to allow direct communication with
the channel 24--e.g. during maintenance or in the event of a
malfunction. It could also be used in other embodiments for routine
communication with the robot arm 6. The rear end face of the
channel also has a display LED 70 which operates in the same way as
the front LED 64 to allow packages to be picked or selected from
the rear. However this LED 70 comprises independent red and green
elements which through various combinations of illumination and
flashing at different rates can convey a number of operational
messages to a user for example not only that a pack is to be
picked, but perhaps that a pack must be input, that multiple packs
must be input, that stock is close to or at empty, that there is an
input or output error, or that the channel has more or less stock
than it is supposed to have. It is of course apparent that the
particular messages and form of display may be chosen by a user to
suit a given implementation.
[0082] Lastly the rear face provides a channel identifier device 72
which is arranged to transmit a signal identifying the channel in
response to an interrogating signal from the robot arm 6. This
allows the robot arm to ensure that it is by the correct
channel.
[0083] Operation of the embodiment set out above will now be
described. In operation, pharmaceutical packages are entered into
the system at a suitable entry point (not shown). The robot arm 6
then picks each package up one at a time, and sends suitable
identifying information to a controlling computer which returns a
command to the robot arm 6 telling it where to place the package.
In alternative arrangements the scanning step may be carried out by
a user (so-called semi-automatic mode). In accordance with the
embodiment of the invention described here, the package could be
placed on one of the conventional shelves 4. Alternatively however,
if the package is a so called "fast mover" it may be placed into
one of the channels 24 of the channel module 12. The robot arm 6
will first interrogate the channel 24 to elicit an identifying
signal and so verify it has the correct channel. It will then place
the package at the top, rear of the channel 24 so allowing the
package to slide down the channel to the pack stop 50 if the
channel is empty or the rear of the stack of packages already in
there. The arm 6 may adjust the width of a channel 24 if necessary
by moving one of the sidewalls 42 thereof. It might also check with
the channel via the central computer, or in alternative embodiments
by means of the infra-red transmitter/receiver arrangement 68, that
there is space for an additional package (e.g. if the rearmost pack
detector 58 is uncovered).
[0084] When a request for a particular pack is received, this will
be processed by the central computer which will either command the
robot arm to retrieve it from one of the shelves 4 if it is not a
fast mover, or if it is a fast mover the computer will send a
dispense instruction to the appropriate channel 24 by means of an
infra-red signal from the infra-red transmitter 32 (FIG. 2) at the
front of the channel module to the receiver 66 at the front of the
channel. This causes the ejector 52 operate by flipping up and
tipping the package over the pack stop 50. The package 38 will then
fall off the end of the channel and onto the soft landing area 26;
and from there onto the conveyor 30. For packages that are
frequently required in multiples, several channels may be used to
store them so that orders requiring multiples of a such a pack may
be fulfilled very quickly by dispensing from multiple channels
simultaneously.
[0085] If further packages are required to make a prescription
these may be dispensed simultaneously either from the channel
module 12 or by means of the arm 6 which can pick a package from
the appropriate shelf 4,38 and place it onto the output chute 36 of
the channel module. Once all the packages of the prescription have
been dispensed onto the conveyor 30, this may be operated to carry
them to a delivery chute or the like so that a customer can receive
them all together much more quickly that if each pack is conveyed
to the delivery point separately.
[0086] In the event of a partial malfunction of the channel module
12--e.g. a loss of main power, drugs may still be dispensed by hand
or the robot arm 6 by using either the manual electric or
mechanical ejectors 60,62. Furthermore this is significantly
facilitated by LEDs being lit on the channels from which drug packs
are required. The LEDs could be powered from a reserve battery
since their current consumption is very low. This means that an
operator does not need to be able to see the packs themselves in
the channel 24.
[0087] A further embodiment of the invention is shown in FIG. 6. In
this embodiment, there are four separate channel modules 74-80
which all differ to some extent from the channel module 12
described with reference to FIG. 2. The two outer modules 74, 80
have significantly deeper channel assemblies 82 than those provided
in the inner modules 76, 78 which are of similar size to those in
the first embodiment. The longer channels 82 of the outer modules
are particularly useful for very fast movers thanks to their high
capacity.
[0088] In contrast to the first embodiment, the individual modules
74-80 do not have their own conveyor system but rather they all use
a common conveyor belt 86 located in front of or below the modules.
The longer, outer channels 82 feed packages on to the conveyor 86
by means of respective soft landing platforms 88 which are opposite
the ends of the channel. Similar soft landing platforms are
provided for the shorter, inner channels 84 directly beneath the
end of these channels, but these are omitted from the Figure for
the sake of clarity. The whole of the channel region comprising the
four modules 74-80 is protected by a screen 90 which prevents packs
falling but of the apparatus.
[0089] As in the first embodiment, an output chute 92 for the robot
arm is provided beneath one of the modules 74 although of course in
this embodiment it is longer since the conveyor 86 is forward of
the module. A chute 92 is shown only in one of the modules in the
Figure, but in practice all of them are provided with similar
chutes This is advantageous in reducing the average distance the
robot arm is required to travel between retrieving a package from
the ordinary shelving and depositing it in an output chute. Also in
common with the first embodiment, some additional shelving 38 is
provided in the dead space below the sloping channels 82, 84.
[0090] FIG. 7 shows the channel region which features in FIG. 6
integrated into the rest of the ordinary shelving 4 which is as
depicted in FIG. 1. Operation of this embodiment up to the packages
28 being carried on the conveyor 86 is exactly the same as in the
first embodiment and will therefore not be described again here.
Again the conveyor 86 can conveniently act as a buffer to collect
all of the packages which are required together in a single order.
This allows them to be output the user altogether which
significantly improves the output speed as compared to outputting
each of them individually when it is considered that conventionally
a package would need to be conveyed all the way to the final
delivery point before transport of the subsequent package is
commenced.
[0091] Newly shown in FIG. 7 is a lift system designated generally
by the numeral 94. It broadly comprises a lift platform 96 which is
driven vertically within a lift shaft 98 from the base of the shaft
to one of two raised openings 100, 102. A small conveyor belt 104
forms the base of the lifting platform 96. The platform may or may
not have side walls and may if necessary have a door or gate both
on the side facing the channel region conveyor 86 and the openings
100, 102 respectively. As will be clearly seen, in operation
packages on the static conveying means 86 are conveyed onto the
conveyor 104 of the lifting platform 96 when the latter is at its
lowest position and the lift platform is then raised until the base
conveyor 104 is level with one of the openings 100, 102. The
packages on the base conveyor 104 may then simply be discharged
onto a delivery chute or slide coupled to the respective opening
100, 102 by operating the conveyor to move the packages forward and
off the platform 96.
[0092] A further embodiment of the invention is shown in FIG. 8. In
fact, this embodiment is simply a combination of three of the
channel modules 12 shown in FIG. 2 with the ordinary shelving
region shown in FIG. 1. A lift module 94 identical to that
described with reference to FIG. 7 is shown at one end of the
channel region. Also shown specifically in this embodiment is a
delivery conveyor 106 coupled with the upper of the two lift
openings 102. The delivery conveyor 106 serves two spiral final
delivery chutes 108, 110 and a swinging diverter bar 112 is
provided across the path of the conveyor 106 to allow a choice to
be made as to which of the delivery chutes 108, 110 a particular
package 38 will fall into.
[0093] The multiple outputs 100,102 of the lift module however
allow simplification of the downstream conveyor system since it is
not required to offer a selection of conveying paths. This also
makes the controlling software less complex and permits a higher
overall output rate.
[0094] FIGS. 9-13 show various alternative configurations for the
lifting module. Turning firstly to FIG. 9, there may be seen a
schematic sectional view of one possible alternative lifting
arrangement. In this arrangement, a lifting platform 114 is
suspended for vertical movement within a shaft 116. The shaft 116
has a lower entry aperture 118 in the region of a conveyor 120 and
three raised openings 122, 124, 126 for outputting packages. Of
course having three openings is purely exemplary and any number may
be provided as convenient. The lift platform 114 is suspended on
two independently driven ropes or belts 128, 130 which are driven
by respective motors 132, 134. One of the ropes 128 is hitched
directly to the platform 114, whilst the second of the ropes 130 is
hitched to a wall member 136 which is itself hingedly attached to
the platform 114.
[0095] In use, packages 38 arrive on the conveyor 120 and are
carried through the entrance aperture 118 and from there they fall
into the wedge-shaped bucket formed by the lift platform 114 and
the side wall 136. When all of the packages 28 for a given order
have been collected, the two motors 132, 134 are operated to raise
the platform 114. When the platform reaches the desired exit
aperture e.g. the second of the three apertures 124 as shown in
FIG. 9, the left hand motor 132 is stopped but the right hand motor
134 is made to continue running to shorten the corresponding rope
130 further so that the platform 114 is tilted up until the
packages 38 slide off the platform and through the exit aperture
124 and onto a conveyor or chute. It will be appreciated from this
that the lifting means may therefore act as a buffer.
[0096] FIG. 10 shows a lift arrangement which is very similar to
FIG. 9 except that the motors 132, 134 are disposed at the bottom
of the shaft with pulleys 136, 138 at the top of the shaft. This
arrangement may be beneficial in allowing easier access to the
motors 132, 134 for maintenance. It also helps to maintain a close
registry between the platform and the output openings.
[0097] A further lift arrangement is shown in FIG. 11 and FIG. 12.
In this arrangement a lift "bucket" is formed with an inclined
conveyor belt 140 as its base and three sloping side walls 142 to
contain the packages. In the lower configuration shown in FIG. 11,
packages 28 are received from a conveyor from the shelving regions
into the bucket. The bucket may then be raised to one of two exit
apertures 146, 148 and the conveyor 140 run to eject to the
packages into a chute or onto a further conveyor.
[0098] A further lift arrangement is shown in FIG. 13. In this
arrangement, a lift box 150 has a sloping floor 152 and is closed
at the front by a roller shutter 154 operated by motor 156. The
shutter 154, when down as shown in the lower part of FIG. 13,
leaves an opening at the top of the box 150 to allow packages to be
put into it. The lift box 150 may then be raised to a higher level
and the shutter motor 156 operated to raise the shutter and thereby
allow packages contained in the lift box 150 to slide off the
sloping floor 152.
[0099] Various possible layouts for the various modules will now be
given with reference to FIGS. 14-19. One possible layout is seen in
FIG. 14. In this, a first conventional shelving region 160 with
associated robot arm (not shown) extends across the width of the
pharmacy. On one side of the conventional shelving region is a
channel region comprising five channel modules 162, 164. Two of the
modules are normal channel modules 162 and the other two are deep
modules 164. Examples of deep and shallow modules may be seen in
the embodiment described with reference to FIGS. 6 and 7.
[0100] In front of each of the deep channel modules 164 is a pack
dropping area 166 which acts to soften the landing of the packages
and to direct them backwardly onto a conveyor 168 which is common
to all five modules and runs beneath the deep modules 164 and in
front of the shallow modules 162. At either end of the conveyor 168
is a lift module 170, each of which has two exits. This arrangement
means that any one of four operator stations 172 may be served by
the apparatus by directing a particular prescription to the
appropriate lift module 170 and then to the appropriate exit of
that lift.
[0101] Another possible layout is shown in FIG. 15. In this
arrangement a conveyor 168 runs underneath three channel modules
162, 162' and a pack dropping area 166 is provided in front of the
modules. The modules 162, 162' are therefore similar to those
described with reference to FIG. 2. However, it will be noted in
this arrangement that only two of the channel modules 162 are
within the area of the conventional shelving 160 and therefore
accessible by the robot arm to fill them. The third module 162' is
directly accessible from the rear to allow it to be filled
manually. This increases the overall input speed to the system
which is possible.
[0102] FIG. 16 shows another possible layout. In this arrangement,
there are two manually filled channel modules 162' opposite two
modules 162 which are filled by the robot arm in the conventional
shelving region 160. The opposite pairs of modules each have
respective pack dropping areas 166 which pass the packages onto a
common conveyor 168 which in turn passes them into the lift module
170. To save space in this layout it could be modified to have just
a single dropping area for all the module 162 and 162', with the
conveyor being provided under the leftmost modules 162 as in the
previous embodiment.
[0103] FIG. 17 shows a tandem layout which is similar to that in
FIG. 16 but wherein a second shelving region 160 and associated
robot arm fill the rightmost channel modules 162. This embodiment
also has a further conveyor 173 between the two conventional
shelving regions 160 which allows stock to be transferred between
them and also allows packages retrieved from the shelving regions
160 (as opposed to the channel modules 162) to be placed into the
lift 170. This is advantageous for example in allowing the lift 170
to act as a buffer to collect all of the packages required together
to fulfill a prescription wherever in the system they may be
stored.
[0104] FIG. 18 simply shows an arrangement in which two separate
shelving regions 160 with associated robot arms feed two channel
modules 162 each but, as in the previous layout, there is a common
lift 170 which may act as a buffer for prescriptions. Again this
embodiment could be modified to have the conveyor as part the
modules 162 and so provided at the bottom thereof to preserve the
modularity of preferred embodiments of the invention.
[0105] Finally, FIG. 19 shows an arrangement in which the storage
part of the apparatus is arranged on the floor above the actual
pharmacy counter from where it is required to issue the
pharmaceutical packs. In this embodiment, there is a shelving
region 160 with associated robot arm feeding two channel modules
162 as in previous embodiments. However, in contrast to previous
embodiments, the conveyor 168 feeds into one of two holes 174 at
either end of it which pass through the floor and open onto
respective conveyors 176 which are towards ceiling level of the
floor below and each of which feeds into three spiral chutes 178
down to a level at which the packages may be collected. As no lift
module(s) is/are required, this represents a cost saving.
[0106] Swinging diverter bars 180 are provided above the conveyors
176 to allow the correct destination chute to be selected. This
embodiment therefore allows six separate operators to receive
packages at their own locations.
[0107] FIG. 20 shows a further embodiment of a channel 200 in
accordance with the invention. In this embodiment the channel 200
comprises a main portion 202 broadly as described previously with
reference to FIGS. 3 to 5; and an auxiliary portion 204. The main
and auxiliary portion 202, 204 are mounted on a pair of rails 206
so as to be manually slidable therealong towards and away from each
other to allow adjustment of the channel width. This could be
indicated by the LED 70 through an appropriate combination of
flashes (e.g. red for widen, green for narrow). The pack detectors
54 to 58; ejection buttons 60,62; infrared detector and receiver
68. display LED 70 and channel identifier device 72 are as
previously described.
[0108] However this embodiment incorporates a different ejector
mechanism 208 described in more detail with reference to FIGS. 21a
and 21b. The ejector mechanism 208 comprises a hood-shaped member
210 which is pivotally mounted with respect to the channel 202. The
pivoting member 210 comprises a base plate 212 and an upstanding
wall 214. A shaft 216 extends down from the base plate 212 and
provides the pivot point at its lower end. Attached to the shaft
216 above the pivot is one end of a shape memory wire 218. The
other end of the wire 218 is anchored to the channel body 202. Also
attached to the shaft 216 above the pivot point is a restoring
spring 220.
[0109] FIG. 21a shows the normal, standby position in which the
baseplate is substantially flush with the surface of the channel
body 202 and a pack 222a is received on it so as to rest against
the endwall 214. when an electrical current is passed through the
shape memory wire 218 its electrical resistance causes it to heat
up which in turn causes it to return to its `hot` shape which is
extended as compared to its ambient state. This extension is
transmitted to the shaft 216 of the pivoting member causing it to
tilt forward. This allows the foremost pack 222a to slide off the
end of the inclined channel and so be ejected. At the same time
however since the rear end of the base plate 212 is raised up the
pack behind 222b cannot slide onto the pivoting member 210 and so
cannot be ejected.
[0110] When current is removed from the wire 218 it will contract
again and, aided by the spring 220, the pivoting member 210 returns
to its standby position. This allows the next pack 222b to slide
onto and be received by the pivoting member 210 ready itself to be
ejected. It will be appreciated therefore that simple, reliable,
one-at-a-time ejection of packs is achieved.
[0111] It will be appreciated by those skilled in the art that the
embodiments described above are merely examples and that there are
many possible variants within the scope of the invention.
* * * * *