U.S. patent application number 12/450674 was filed with the patent office on 2010-06-10 for product filling system.
This patent application is currently assigned to Micron PharmaWorks, Inc.. Invention is credited to Ben Brower, Peter Buczynsky, Ingo Federle.
Application Number | 20100139222 12/450674 |
Document ID | / |
Family ID | 39876121 |
Filed Date | 2010-06-10 |
United States Patent
Application |
20100139222 |
Kind Code |
A1 |
Federle; Ingo ; et
al. |
June 10, 2010 |
PRODUCT FILLING SYSTEM
Abstract
A product filling system (100) includes a first multi-lane
conveyor (106) for receiving products and a second multi-lane
conveyor (110) for receiving the products from the first multi-lane
conveyor (106). The first multi-lane conveyor (106) and the second
multi-lane conveyor (110) include a plurality of independently
movable belts controlled by a controller (128). First and second
camera systems (108, 112) inspect first and second portions of the
products on the plurality of belts and judge whether each of the
products is defective or not defective.
Inventors: |
Federle; Ingo; (Wesley
Chapel, FL) ; Brower; Ben; (Wesley Chapel, FL)
; Buczynsky; Peter; (Odessa, FL) |
Correspondence
Address: |
POSZ LAW GROUP, PLC
12040 SOUTH LAKES DRIVE, SUITE 101
RESTON
VA
20191
US
|
Assignee: |
Micron PharmaWorks, Inc.
Odessa
FL
|
Family ID: |
39876121 |
Appl. No.: |
12/450674 |
Filed: |
April 15, 2008 |
PCT Filed: |
April 15, 2008 |
PCT NO: |
PCT/US08/04842 |
371 Date: |
October 6, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60907789 |
Apr 17, 2007 |
|
|
|
Current U.S.
Class: |
53/474 ;
53/266.1 |
Current CPC
Class: |
B65B 57/14 20130101;
B65B 57/20 20130101 |
Class at
Publication: |
53/474 ;
53/266.1 |
International
Class: |
B65B 5/08 20060101
B65B005/08 |
Claims
1. A product filling system comprising: a controller; a driving
device coupled to the controller; a multi-lane conveyor including a
plurality of belts independently movable by the driving device,
each of the plurality of belts including product storing means for
storing a plurality of products; and a camera system coupled to the
controller, the camera system disposed in proximity to the
plurality of belts to inspect each of the plurality of products,
wherein the controller is configured to control the driving device
to independently move each of the plurality of belts.
2. The product filling system of claim 1, wherein the driving
device includes a plurality of motors respectively coupled to the
plurality of belts, wherein the controller is configured to
activate or de-activate a particular one of the plurality of motors
to independently move each of the plurality of belts.
3. The product filling system of claim 1, further comprising a
vacuum pump coupled to the controller for maintaining the products
on the belts of the multi-lane conveyor while the camera system
performs the inspection, wherein the product storing means includes
a plurality of apertures for receiving vacuum from the vacuum
pump.
4. The product filling system of claim 3, further comprising: a
blow-off device for releasing the products from the plurality of
belts; and a counting sensor coupled to the controller and disposed
in proximity to the plurality of belts for counting a number of the
products released from the plurality of belts.
5. The product filling system of claim 4, further comprising a
verification sensor coupled to the controller and disposed in
proximity to a rejection receptacle to verify release of the
products by the blow-off device.
6. The product filling system of claim 1, further comprising:
another multi-lane conveyor including a plurality of primary
feeding belts independently movable by the driving device, each of
the plurality of primary feeding belts including a plurality of
holders for storing the plurality of products; and another camera
system coupled to the controller and disposed in proximity to the
plurality of primary feeding belts to inspect each of the plurality
of products, wherein the controller is configured to control the
driving device to independently move each of the plurality of
primary feeding belts.
7. The product filling system of claim 6, wherein the another
camera system inspects a first portion of the plurality of products
and the camera system inspects a second portion of the plurality of
products.
8. The product filling system of claim 7, wherein the another
camera system includes a plurality of first cameras disposed to
inspect the first portion of the plurality of products in the
holders of the plurality of primary feeding belts, and the camera
system include a plurality of second cameras disposed to inspect
the second portion of the plurality of products on the plurality of
transfer belts, wherein the controller is configured to
independently control movement of a particular one of the plurality
of primary feeding belts and the plurality of transfer belts based
upon an inspection performed by its respective one of the plurality
of first cameras or the plurality of second cameras.
9. The product filling system of claim 7, wherein the camera system
and the another camera system judge whether the product is
defective or not defective and count the number of products judged
to be defective and the number of products judged to not be
defective, wherein the controller is configured to control the
driving device to independently move each of the plurality of belts
in accordance with the count performed by the camera system and the
another camera system.
10. A product filling system comprising: a primary feeding belt
having holders for storing products in a state in which a first
portion of the products faces in a first direction; a first camera
system configured to inspect the first portion of the products on
the primary feeding belt; a transfer belt for receiving the
products from the primary feeding belt, the transfer belt including
apertures for storing the products in a state in which a second
portion of the products faces in a second direction; a second
camera system configured to inspect the second portion of the
products on the transfer belt; and a controller coupled to the
first and second camera systems, the controller configured to
independently control the primary feeding belt and the transfer
belt.
11. The product filling system of claim 10, further comprising a
vacuum pump for providing vacuum to the apertures to maintain the
products on the transfer belt while the second camera system
inspects the second portion.
12. The product filling system of claim 10, further comprising: a
counting sensor coupled to the controller and disposed in proximity
to the transfer belt for counting a number of the products removed
from the transfer belt, wherein the controller is configured to
independently control the primary feeding belt and the transfer
belt based upon the count performed by the counting sensor.
13. The product filling system of claim 10, further comprising a
rejection receptacle coupled to the transfer belt for receiving
products based upon the inspection performed by one of the first
and second camera systems.
14. The product filling system of claim 13, further comprising a
verification sensor coupled to the controller and disposed in
proximity to the rejection receptacle to verify reception of the
products by the rejection receptacle, wherein the controller is
configured to independently control the primary feeding belt and
the transfer belt based upon the verification performed by the
verification sensor.
15. The product filling system of claim 10, wherein the controller
is configured to control movement of the primary feeding belt and
the transfer belt based upon the inspection performed by the first
camera system or the second camera system.
16. The product filling system of claim 10, wherein the first and
second camera systems judge whether the product is defective or not
defective and count the number of products judged to be defective
and the number of products judged to not be defective, wherein the
controller is configured to control movement of the primary feeding
belt and the transfer belt based upon the inspection and the count
performed by the first camera system or the second camera
system.
17. A product filling system comprising: a belt including storage
means for storing the products in a state in which a portion of the
products faces in a predetermined direction; a camera system
configured to inspect the portion of the products on the belt and
to count the number of inspected products; a counting sensor
disposed in proximity to the belt for counting a number of the
products released from the belt; and a controller configured to
control the belt based upon the counting performed by the counting
sensor and the camera system.
18. The product filling system of claim 17, further comprising a
rejection receptacle for receiving products based upon the
inspection performed by the camera system.
19. The product filling system of claim 18, further comprising a
verification sensor coupled to the controller and disposed in
proximity to the rejection receptacle to verify reception of the
products by the rejection receptacle, wherein the controller is
further configured to control the belt based upon the verification
performed by the verification sensor.
20. The product filling system of claim 17, further comprising a
vacuum pump coupled to the controller for maintaining the products
on the belt while the first camera system performs the
inspection.
21. The product filling system of claim 17, wherein the controller
is configured to control the belt based upon the inspection
performed by the camera system.
22. A product filling system comprising: a first multi-lane
conveyor for receiving products, the first multi-lane conveyor
including a plurality of independently movable primary feeding
belts having holding devices for storing the products in a state in
which a first portion of the products faces in a first direction; a
first camera system configured to inspect the first portion of the
products on the plurality of primary feeding belts of the first
multi-lane conveyor; a second multi-lane conveyor for receiving the
products from the first multi-lane conveyor, the second multi-lane
conveyor including a plurality of independently movable transfer
belts having apertures for storing the products in a state in which
a second portion of the products faces in a second direction; a
second camera system configured to inspect the second portion of
the products on the plurality of transfer belts of the second
multi-lane conveyor; and a controller configured to independently
control each of the primary feeding belts and the transfer
belts.
23. The product filling system of claim 22, wherein the first and
second camera systems judge whether each of the products is
defective or not defective.
24. The product filling system of claim 23, further comprising a
rejection receptacle for receiving products judged to be defective
by one of the first camera system and the second camera system.
25. The product filling system of claim 22, wherein the second
camera system is further configured to count the products judged to
be not defective for each of the transfer belts, and the controller
is further configured to suspend movement of one of the transfer
belts when the second camera system has counted a predetermined
number of products judged to be not defective for the one of the
transfer belts.
26. A method of inspecting products and distributing inspected
products into containers, the method comprising: distributing the
products on a first multi-lane conveyor including a plurality of
independently controlled primary feeding belts in a state in which
a first portion of the products faces in a first direction;
inspecting the first portion of the products to judge if the
products are defective or not defective; distributing the products
on a second multi-lane conveyor including a plurality of
independently controlled transfer belts in a state in which a
second portion of the products faces in a second direction;
inspecting the second portion of the products to judge if the
products are defective or not defective; and filling the containers
with the products judged to be not defective based upon the
inspecting of the first portion and based upon the inspecting of
the second portion.
27. The method of claim 26, further comprising counting a number of
the products judged to be defective or not defective.
28. The method of claim 27, depositing products judged to be
defective in a rejection receptacle.
29. The method of claim 28, further comprising verifying that a
number of the products deposited in the rejection receptacle is
equal to the number of products judged to be defective.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is related to and claims priority
from pending U.S. Provisional Application No. 60/907,789 filed Apr.
17, 2007.
TECHNICAL FIELD
[0002] The technical field relates generally to inspecting and
distributing of pills, tablets, capsules, and the like, and, more
particularly, to an apparatus and method for inspecting such pills,
tablets, capsules, and the like and distributing into
containers.
BACKGROUND
[0003] In the post-production stage of small objects such as
tablets, pills, capsules, and the like, which will be referred to
here collectively as products, it is necessary to inspect the
products for defects, remove products judged as being defective,
and accurately fill a container, package or the like with the
products judged not to be defective. Inspection can be performed
manually, but such an approach is not feasible for a production
line that may be producing or packaging thousands of the products
per hour.
[0004] An automated product filling system can be used to perform
the above container filling or packaging. However, conventional
product filling systems fail to achieve the level of inspection
needed, and also fail to include necessary safeguards for ensuring
that products judged as being defective are not inadvertently
packaged or bottled and that an accurate number of non-defective
products are being packaged or bottled.
[0005] Recently, automated product filling systems are being
operated in multi-product environments in which various products
are being distributed to containers on the same system. The system
may need to distinguish between different products to ensure that a
particular product is distributed into its designated container,
particularly when the product is a tablet or pill for prescription
medicine.
SUMMARY
[0006] Accordingly, one or more embodiments of the present
invention provide a product filling system including a first
multi-lane conveyor having a plurality of independently movable
primary feeding belts with holding devices for storing the products
in a state in which a first portion of the products faces in a
first direction. A first camera system is configured to inspect the
first portion of the products on the plurality of primary feeding
belts. The system further includes a second multi-lane conveyor for
receiving the products from the first multi-lane conveyor. The
second multi-lane conveyor includes a plurality of independently
movable transfer belts, each of which has apertures for storing the
products in a state in which a second portion of the products faces
in a second direction. A second camera system is configured to
inspect the second portion of the products on the plurality of
transfer belts of the second multi-lane conveyor. A controller is
configured to independently control each of the primary feeding
belts and the transfer belts.
[0007] The first and second camera systems judge whether each of
the products is defective, not defective or missing. The system can
include a rejection receptacle for receiving products judged to be
defective by the first camera system and the second camera
system.
[0008] The camera systems can be further configured to count the
products judged to be not defective and the products judged to be
defective, and the controller can be further configured to suspend
movement of one of the transfer belts when a predetermined number
of products judged to be not defective for the one of the transfer
belts has been released into a container.
[0009] One or more embodiments of the present invention also
provide a method of inspecting products and distributing the
inspected products into containers. The method according to a first
aspect includes distributing the products on a first multi-lane
conveyor including a plurality of independently controlled primary
feeding belts in a state in which a first portion of the products
faces in a first direction; inspecting the first portion of the
products to judge if the products are defective or not defective;
distributing the products on a second multi-lane conveyor including
a plurality of independently controlled transfer belts in a state
in which a second portion of the products faces in a second
direction; inspecting the second portion of the products to judge
if the products are defective or not defective; and filling the
containers with the products judged to be not defective based upon
the inspecting of the first portion and based upon the inspecting
of the second portion.
[0010] The method according to a second aspect further includes
counting a number of the products judged to be defective or not
defective.
[0011] The method according to a third aspect further includes
depositing products judged to be defective in a rejection
receptacle and verifying that a number of the products deposited in
the rejection receptacle is equal to the number of products judged
to be defective.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying figures, which together with the detailed
description below are incorporated in and form part of the
specification, serve to further illustrate various exemplary
embodiments and to explain various principles and advantages in
accordance with the present invention.
[0013] FIG. 1A is a front perspective view of a product filling
system according to an exemplary embodiment;
[0014] FIG. 1B is rear perspective view of the product filling
system;
[0015] FIG. 1C is a left side elevation view of the product filling
system;
[0016] FIG. 1D is a top plan view of the product filling
system;
[0017] FIG. 1E is a right side elevation view of the product
filling system;
[0018] FIG. 2 is a block diagram of the product filling system
according to the exemplary embodiment;
[0019] FIG. 3 is a flow diagram illustrating an exemplary method of
operating the product filling system;
[0020] FIG. 4A is an exemplary top plan view of the junction
between the first and second multi-lane conveyers; and
[0021] FIG. 4B is an exemplary bottom plan view of the junction
between the first and second multi-lane conveyers.
DETAILED DESCRIPTION
[0022] The instant disclosure is provided to further explain in an
enabling fashion the best modes of performing one or more
embodiments of the present invention. The disclosure is further
offered to enhance an understanding and appreciation for the
inventive principles and advantages thereof, rather than to limit
in any manner the invention. The invention is defined solely by the
appended claims including any amendments made during the pendency
of this application and all equivalents of those claims as
issued.
[0023] It is further understood that the use of relational terms
such as first and second, and the like, if any, are used solely to
distinguish one from another entity, item, or action without
necessarily requiring or implying any actual such relationship or
order between such entities, items or actions. It is noted that
some embodiments may include a plurality of processes or steps,
which can be performed in any order, unless expressly and
necessarily limited to a particular order; i.e., processes or steps
that are not so limited may be performed in any order.
[0024] Referring to FIGS. 1A-1E, a product filling system 100 for
sorting, inspecting and filling small objects such as tablets,
pills, capsules, and the like, which will be referred to here
collectively as products, into containers according to an exemplary
embodiment will be discussed. Although not shown here, the product
filling system 100 can be mounted to or integrated within a
mono-block bottle handling system.
[0025] The product filling system 100 includes a bulk hopper 102
for feeding or filling the products into a flood feeder 104, a
first multi-lane (inspection) conveyor 106 for receiving the
products from the flood feeder 104, a first camera system 108 for
inspecting the products on the first multi-lane conveyor 106, a
second multi-lane (pickup) conveyor 110 for receiving the products
from the first multi-lane conveyor 106, a second camera system 112
for inspecting the products on the second multi-lane conveyor 110,
a rejection receptacle 114 for receiving products judged to be
defective, and stationary funnels 116 for receiving products judged
not to be defective, counting the products and distributing (or
dispensing) the products to containers 118. The above portions of
the product filling system 100 will be discussed more fully
below.
[0026] The bulk hopper 102 includes a product hopper 120 for
receiving the products from a source, and a vibratory feeder 124
for feeding the products into the flood feeder 104. The vibratory
feeder 124 can be coupled to a capacitive proximity sensor mounted
on the flood feeder 104 to feed the products into the flood feeder
104 on demand. The flood feeder 104 is for placing the products
onto the first multi-lane conveyer 106. The flood feeder 104 can
be, for example, a three stage flood feed, including three
independent brushes and three independent stirring heads.
[0027] The first multi-lane conveyor 106 includes a plurality of
belts 106a-106e as shown in FIGS. 1B and 1D, which will be referred
to here as primary feeding belts. The primary feeding belts
106a-106e can be, for example, timing type belts, including
fixtures or holding devices 402 (see FIGS. 4A-4B) attached thereto
(product storing means). Generally, the primary feeding belts
106a-106e are configured to receive the products from the flood
feeder 104 and securely store and transport the products in the
holding devices 402 in a state in which a first portion of the
products faces upwards or generally in a first direction. The
product can remain in the holding devices 402 by force of gravity
or by receiving vacuum from a vacuum pump (not shown). The holding
devices 402 can include machined pockets which accommodate and
transport the product. Although in this example five primary
feeding belts 106a-106e are shown, it should be appreciated that
the product filling system 100 is not limited to this number of
feeding belts. For example, the system 100 could include as few as
one primary feeding belt. 100281 The first multi-lane conveyor 106
can also include dead plates (not shown) located between adjacent
belts in order to fill the gaps between the primary feeding belts
106a-106e. The dead plates can be composed of, for example, Delrin,
and can be formed to be slightly chamfered in order to force
products toward the primary feeding belts 106a-106e.
[0028] A driving device 126 is coupled to the primary feeding belts
106a-106e for independently moving each of the primary feeding
belts 106a-106e based upon control signals received from a
controller 128 (see FIG. 2). In this exemplary embodiment, the
driving device 126 includes a plurality of servo-motors 126a-126e
mechanically coupled to the primary feeding belts 106a-106e,
respectively. The controller 128 can activate or de-activate a
particular one of the servo-motors 126a-126e to move or stop
movement of a respective one of the primary feeding belts
106a-106e. Although in this example the servo-motors 126a-126e are
shown coupled to the primary feeding belts 106a-106e at a bottom
side of the system 100, it should be appreciated that the product
filling system 100 is not limited to this particular configuration.
For example, the system 100 could include motors inside the primary
feeding belts 106a-106b.
[0029] The first camera system 108 is located in proximity to the
primary feeding belts 106a-106e to inspect each of the plurality of
products in the holders. Preferably, the first camera system 108 is
disposed above the primary feeding belts 106a-106e for inspecting a
first portion, such as a top side, of the products. The first
camera system 108 is configured to inspect the products on each
primary feeding belt 106a-106e independently. Inspecting of the
products can include, for example, an evaluation of the color and
shape of the product, a determination of whether a product is
present, and/or a determination of whether the product is broken or
chipped. The evaluation can be used to distinguish the product
from, for example, a different product that may have been earlier
or is simultaneously being distributed within the system 100 to
designated containers. The first camera system 108 can be, for
example, a scanware Lynx-Spectra system for performing full color
inspection or a scanware Lynx-11 system for performing black and
white inspection. Further, the first camera system 108 can include
separate first cameras (see FIG. 2) respectively disposed above the
primary feeding belts 106a-106e as well as a single camera for all
or some of the belts 106a-106e.
[0030] The first camera system 108 can further be configured to
count the number of products judged to be defective and the number
of products judged to not be defective. Alternatively, a separate
count sensor can be located near the first camera system 108 to
perform the counting. The first camera system 108 (or the separate
counter sensor) preferably sends data regarding the count and the
inspection to a memory associated with the controller 128 so that
it can independently control the primary feeding belts 106a-106e
based upon the data. The driving device 126 can move all of the
primary feeding belts 106a-106e to start a feed cycle together, but
some belts may be stopped by the controller 128 before others as
each belt reaches a correct product count.
[0031] As shown in FIG. 1D, the second multi-lane conveyor 110 also
includes a plurality of belts 110a-110e, which will be referred to
here as transfer belts. The transfer belts 110a-110e can be, for
example, urethane based belts that are machined to a specific
format to have apertures 406 (see FIGS. 4A-4B) or cavities (product
storing means) for accommodating the products. The transfer belts
110a-110e are mechanically and electrically aligned with the
primary feeding belts 106a-106e and synchronized with the primary
feeding belts 106a-106e so that the products can be smoothly
transferred from the holding devices 402 to apertures 406 of the
transfer belts 110a-110e. Particularly, the timing of the movement
of the transfer belts 110a-110e and the primary feeding belts
106a-106e should be sufficiently synchronized so that a product in
one of the holding devices arrives at an aperture of the transfer
belt 110. Although in this example five transfer belts 110a-110e
are shown, it should be appreciated that the product filling system
100 is not limited to this number.
[0032] A driving device 130 is coupled to the transfer belts
110a-110e for independently moving each of the transfer belts
110a-110e based upon control signals received from the controller
128. In this exemplary embodiment, the driving device 130 includes
a plurality of servo-motors 130a-130e coupled respectively to the
transfer belts 110a-110e. The controller 128 can activate or
de-activate a particular one of the servo-motors 130a-130e to move
or stop movement of a respective one of the transfer belts
110a-110e.
[0033] The transfer belts 110a-110e can be coupled to a vacuum pump
202 (see FIG. 2) so that the products can be stored on the transfer
belts 110a-110e in a state in which the products face downwards.
That is, the vacuum pump 202 maintains the products in or on the
apertures 406 of the transfer belts 110a-110e. A defective product
removal device such as, for example, a blow off device 204 (see
FIG. 2), can be disposed in proximity to the transfer belts
110a-110e for removing products judged to be defective. The
pneumatic blow off device 202 can be controlled by the same
controller 128 that controls the servo-motors 130a-130e. The blow
off device 202 can be activated by the controller 128
electronically (via control signals) or mechanically via mechanical
coupling with, for example, the driving device 130. The blow off
device 202 can be a pneumatic blow off device 202. Alternatively,
defective product removal device can be an electro-mechanical
strip-off device.
[0034] The second camera system 112 is disposed below the second
multi-lane conveyor 110 for inspection of a second portion, such as
a bottom side, of the products. The second camera system 112 can
also be configured to count and inspect the products on each
transfer belt independently, and to adjust the count when it judges
a product judged to not be defective by the first camera as
defective. Similarly to the first camera system 108, the second
camera system 112 can also be a Scanware Lynx-Spectra system or
scanware Lynx-11 system and can include separate cameras
respectively disposed below the transfer belts 110a-110e.
[0035] The rejection receptacle 114 is disposed below the second
multi-lane conveyor 110 for receiving products judged to be
defective by either the first camera system 108 or second camera
system 112. The rejection receptacle 114 can include a verification
sensor 206 (see FIG. 2) coupled to the controller 128 to verify
that products judged as defective were actually received by the
rejection receptacle 114. The controller 128 can be configured to
independently control the primary feeding belts 106a-106e and the
transfer belts 110a-110e based upon the verification performed by
the verification sensor 206.
[0036] The stationary funnels 116 are for receiving products judged
not to be defective by the first camera system 108 and second
camera system 112 from the transfer belts 110a-110e of the second
multi-lane conveyor 110. A beam sensor 208 (see FIG. 2) can be
disposed above the stationary funnels 112 to verify that the
products actually passed into the funnels 116 and to verify the
product count. The stationary funnels 116 can distribute the
products to containers 118 disposed below the stationary funnels
116. The controller 128 can be configured to independently control
the primary feeding belts 106a-106e and the transfer belts
110a-110e based upon the verification performed by the beam sensor
208. For example, when a container 118 at a particular transfer
belt receives a predetermined number of the product, that
particular transfer belt can be stopped, while transfer belts of
containers which have not yet received the predetermined number of
the products continue to be moved. It should be noted that the
stationary funnels 116 are optional.
[0037] The product filling system 100 will now be discussed with
reference to the block diagram of FIG. 2. The system 100 can
include one or more motion controllers 210 coupled between the
controller 128 and the drive devices 126, 130 to perform
independent control of the primary feeding belts 106a-106e of the
first multi-lane conveyor 106 and the transfer belts 110a-110e of
the second multi-lane conveyor 110. The motion controller 210 can
be, for example, an Allen Bradley servo drive or equivalent device.
The motion controllers 210 and the motors 126, 130 can all be
considered a drive device.
[0038] The controller 128 is also coupled to bottom side and top
side inspection vision system controllers 212, 214 for performing
control and collecting data from the individual cameras of the
first and second cameras systems 108, 112. The inspection vision
system controllers 212, 214 can be a PC/frame grabber combination
with vision software.
[0039] The controller 128 is also coupled to the flood feeder 104
to control the feeding of the products onto the first multi-lane
conveyer 106. For example, the controller 128 can control the
brushes and stirring heads of the flood feeder 104.
[0040] The controller 128 is also coupled to the reject
verification sensor 206 and the fill/count verification sensor 208.
As discussed above, the verification sensor 206 verifies that
products judged as defective were actually received by the
rejection receptacle 114. A number of the verification sensors 206
can be respectively disposed between each of the transfer belts
110a-110e and the rejection receptacle 114 to perform independent
verification for each lane. Similarly, a number of the beam sensors
208 can be respectively disposed between each of the transfer belts
110a-110e and the containers 118 to perform independent
verification that products were deposited in a container for each
lane.
[0041] The controller 128 can also be coupled to an operator
interface/human machine interface (HMI) 216 so that a user can view
the data collected by the various sensors and cameras, and perform
manual control of, for example, the drive device (motion
controllers 210 and the motors 126, 130) or the vacuum pump
202.
[0042] The controller 128 executes instructions stored in an
associated memory to control the belts based upon, for example,
data from the first and second camera systems 108, 112, data from
the beam or verification sensors, or control instructions received
from the operator interface 210. For example, the controller 128
can control the transfer belts 110a-110e so that movement of one of
the transfer belts 110a-110e is suspended when the second camera
system 112 has counted a predetermined number of products judged to
be not defective for the one of the transfer belts 110a-110e.
Particularly, when a particular container at the transfer belt
receives a predetermined number of the products, or is `full`, the
controller 128 can stop movement of that particular transfer belt.
In another example, if the verification sensor 206 cannot verify
that a defective product was received by the rejection receptacle
114, the controller 128 can stop the system 100 and operation can
be suspended until reset by authorized personnel to thereby prevent
defective products from entering the containers.
[0043] The controller 128 can be coupled to the various components
by, for example, a bus or other conventional means. Each of the
first and second cameras 108, 112 and various sensors can be
configured to output data such as inspection results and counting
data to the associated memory. The controller 128 can include
various logical elements such as a shift register and flags for
storing the various results such as count and inspection data to
create a virtual representation of the products on the
conveyors.
[0044] Referring to FIG. 3, an exemplary method of operating the
product filling system 100 will be discussed in which tablets as
the product are inspected. Initially, at 305, the tablets are
inserted into the product hopper 120 in bulk. The vibratory feeder
124 coupled to the product hopper 120 feeds the tablets into the
flood feeder 104. At 310, the flood feeder 104 distributes the
tablets onto the primary feeding belts 106a-106e of the first
multi-lane conveyor 106. The flood feeder 104 aids in filling as
many of the holders 406 of the primary feeding belts 106a-106e as
possible. The tablets are stored in the holders 406 on the primary
feeding belts 106a-106e in a state in which a first portion of the
tablets faces in a first direction. That is, the tablets are stored
in the holders or fixtures of the primary feeding belts facing
upwards.
[0045] At 315, the primary feeding belts 106a-106e are driven by
the servomotors 126a-126e or other type of motor so that the
tablets pass under the first camera system 108 for inspecting a
first portion such as the top side of the tablets. The first camera
system 108 judges whether the first portion of the tablets is
defective, non-defective or missing, and counts each defective or
non-defective tablet.
[0046] After the inspection, at 320 the tablets are transferred
from the primary feeding belts 106a-106e of the first multi-lane
conveyor 106 to the transfer belts 110a-110e of the second conveyor
110. Here, the vacuum pump 202 can pick up the tablets from the
primary feeding belts 106a-106e and maintain the tablets suspended
on the transfer belts 110a-110e in a state in which a second
portion of the tablets faces in a second direction (facing
downwards).
[0047] At 325, the second camera 108 can inspect the second portion
(reverse side) of the tablets while they are suspended on the
transfer belts 110a-110e. The second camera 108 also counts each
tablet after inspection.
[0048] At 330, it is determined if the tablet is defective based
upon the inspection performed by the first and second cameras 108,
114. If a tablet is judged to be defective (YES at 330), at 340 it
is released from the transfer belt into a particular one of the
rejection receptacles 114. Here, the blow off device 204 can remove
the tablet judged to be defective to be deposited in the rejection
receptacle 114. At 345, the reject verification sensors 206 in the
rejection receptacles 114 verify that the tablet judged to be
defective is actually deposited into the rejection receptacle 114.
If the sensors 206 cannot verify that the tablet was deposited into
the rejection receptacle (NO at 345), the product filling system
100 can be shutdown at 350
[0049] Returning to 330, if a tablet is determined not to be
defective (NO at 330), at 335 it is decoupled from the transfer
belts so that it is deposited into one of the containers 118 via
the stationary funnels 116. At 355, the fill/count verification
sensors 208 disposed in the stationary funnels 116 count the number
of tablets inserted into respective funnels. For example, when the
count is greater than a predetermined number of tablets (NO at
350), the product filling system 100 can be temporarily shutdown at
355 so that a container can be removed, or a container can be
maintained at a particular transfer belt longer than containers at
adjacent belts in order to continue to add more tablets. Otherwise,
each of the transfer belts 116a-116e continue to be driven by the
motors 130 until a predetermined number of the tablets are counted
and inserted into a respective funnel at the end of the transfer
belts.
[0050] Returning to 330, the determination of whether a tablet is
defective can be done based upon parameters input to the controller
128 by a user at the operator interface 210. For example, a tablet
may be judged to be defective if both or one of the sides of the
tablet do not conform to a certain shape or color. That is, a
product may be judged to be defective not due to a manufacturer
error, but because it is not the product intended for a particular
container. For example, if the system 100 was used to inspect and
distribute a first type of tablets for a certain prescription
medicine at a first time period, there is a chance that the first
type of tablets may remain in the system 100 even when it is being
used at a later time to inspect and distribute a second type of
tablets. In this case, the camera systems 108, 112 can be
configured to recognize the first type of tablets so that it is
immediately judged as defective when the system 100 is being used
to inspect and distribute the second type of tablets. In another
example, the system 100 can be used to recognize tablets that are
defective due to a manufacturer error.
[0051] Referring to FIGS. 4A-4B the junction between the first and
second multi-lane conveyers 106, 112 will be discussed in more
detail. The holders 402 of the primary feeding belts 106a-106e
store the tablets 404 in a state in which a top (first) portion of
the products faces upwards (in a first direction). When the holders
402 arrive under the transfer belts 110a-110e, the vacuum pump 202
(FIG. 2) draws the tablets 404 from the holders 406 to the
apertures 406 of the transfer belts 106a-106e. That is, the vacuum
pump 202 can apply vacuum to the apertures 406 so that the tablets
404 are stored on the transfer belts 110a-110e in a state in which
a bottom (second) portion of the products faces downwards (in a
second direction) as shown in FIG. 4B.
[0052] Therefore, the present disclosure concerns a product filling
system 100 comprising: a controller 128; a driving device 126, 130
coupled to the controller 128; a multi-lane conveyor 110 including
a plurality of belts independently movable by the driving device,
each of the plurality of belts including product storing means 406
for storing a plurality of products 404; and a camera system 214
coupled to the controller 128 and disposed in proximity to the
plurality of belts to inspect each of the plurality of products,
wherein the controller 128 is configured to control the driving
device 126, 130 to independently move each of the plurality of
belts.
[0053] The driving device 126, 130 can include a plurality of
motors 130 respectively coupled to the plurality of belts, and the
controller 128 can be configured to activate or de-activate a
particular one of the plurality of motors to achieve independent
motion.
[0054] A vacuum pump 202 can be coupled to the controller 128 for
maintaining the products on the belts of the multi-lane conveyor
while the camera system 214 performs the inspection. The product
storing means 406 is preferably a plurality of apertures 405 for
receiving vacuum from the vacuum pump 202.
[0055] A blow-off device 204 can release the products from the
plurality of belts; and a counting sensor such as the verification
sensor 208 or the reject verification sensor 206 is coupled to the
controller and disposed in proximity to the plurality of belts for
counts a number of the products released from the plurality of
belts.
[0056] The product filling system can include another multi-lane
conveyor 106 including a plurality of primary feeding belts
independently movable by the driving device 126, 210, each of the
plurality of primary feeding belts including a plurality of holders
402 for storing the plurality of products; and another camera
system 108 coupled to the controller 128 and disposed in proximity
to the plurality of primary feeding belts to inspect each of the
plurality of products. The controller 128 can be configured to
control the driving device 126, 210 to independently move each of
the plurality of primary feeding belts.
[0057] The another camera system 108 inspects a first portion of
the plurality of products and the camera system 112 inspects a
second portion of the plurality of products. The another camera
system 108 can include a plurality of first cameras disposed to
inspect the first portion of the products in the holders of the
plurality of primary feeding belts, and the camera system 112
include a plurality of second cameras disposed to inspect the
second portion of the products on the plurality of transfer belts.
The controller can be configured to independently control movement
of a particular one of the plurality of primary feeding belts and
the plurality of transfer belts based upon an inspection performed
by its respective first camera or second camera.
[0058] The camera systems 108, 112 judge whether the product is
defective or not defective and count the number of products judged
to be defective and the number of products judged to not be
defective. The controller 128 is configured to control the driving
device 126, 210 to independently move each of the plurality of
belts in accordance with the count performed by the camera system
and the another camera system.
[0059] That is, although the system 100 shown in FIG. 1A has two
multi-lane conveyors, the system 100 could alternatively have a
single multi-lane conveyor. For example, the system 100 could only
include the second multi-lane conveyor 110.
[0060] The disclosure also concerns a product filling system 100
comprising: a primary feeding belt 106a-106e having holders 402 for
storing products in a state in which a first portion of the
products faces in a first direction; a first camera system 108
configured to inspect the first portion of the products on the
primary feeding belt; a transfer belt 110a-110e for receiving the
products from the primary feeding belt, the transfer belt including
apertures 406 for storing the products in a state in which a second
portion of the products faces in a second direction; a second
camera system 112 configured to inspect the second portion of the
products on the transfer belt 110a-110e; and a controller 128
coupled to the first and second camera systems 108, 112, the
controller 128 configured to independently control the primary
feeding belt 106a-106e and the transfer belt 110a-110e.
[0061] The system 100 can include a vacuum pump 202 for providing
vacuum to the apertures 406 to maintain the products on the
transfer belt while the second camera system inspects the second
portion. A counting sensor 208 coupled to the controller and
disposed in proximity to the transfer belt counts a number of the
products removed from the transfer belt, and the controller can be
configured to independently control the primary feeding belt and
the transfer belt based upon the count performed by the counting
sensor 208.
[0062] A rejection receptacle 114 coupled to the transfer belt
receives products based upon the inspection performed by one of the
first and second camera systems, and a verification sensor 206
coupled to the controller and disposed in proximity to the
rejection receptacle verifies reception of the products by the
rejection receptacle. The controller 128 can be configured to
independently control the primary feeding belt and the transfer
belt based upon the verification performed by the verification
sensor.
[0063] The controller can be configured to control movement of the
primary feeding belt and the transfer belt based upon the
inspection performed by the first camera system or the second
camera system, particularly whether the product is defective or not
defective and count the number of products judged to be defective
and the number of products judged to not be defective.
[0064] That is, although the system 100 shown in FIG. 1A has two
multi-lane conveyors which each include multiple belts, the system
100 could alternatively have two multi-lane conveyors which each
include only a single belt.
[0065] The disclosure also concerns a product filling system 100
comprising a belt including storage means for storing the products
in a state in which a portion of the products faces in a
predetermined direction; a camera system configured to inspect the
portion of the products on the belt and to count the number of
inspected products; a counting sensor disposed in proximity to the
belt for counting a number of the products released from the belt;
and a controller configured to control the belt based upon the
counting performed by the counting sensor and the camera
system.
[0066] A rejection receptacle receives products based upon the
inspection performed by the camera system and a verification sensor
coupled to the controller and disposed in proximity to the
rejection receptacle to verify reception of the products by the
rejection receptacle. The controller is further configured to
control the belt based upon the verification performed by the
verification sensor. A vacuum pump coupled to the controller for
maintaining the products on the belt while the first camera system
performs the inspection, and the controller is configured to
control the belt based upon the inspection performed by the camera
system.
[0067] That is, although the system 100 shown in FIG. 1A has two
multi-lane conveyors which each include multiple belts, the system
100 could alternatively have a single multi-lane conveyor
multi-lane conveyors which includes only a single belt.
[0068] This disclosure is intended to explain how to fashion and
use various embodiments in accordance with the invention rather
than to limit the true, intended, and fair scope and spirit
thereof. The invention is defined solely by the appended claims, as
they may be amended during the pendency of this application for
patent, and all equivalents thereof. The foregoing description is
not intended to be exhaustive or to limit the invention to the
precise form disclosed. Modifications or variations are possible in
light of the above teachings. The embodiment(s) was chosen and
described to provide the best illustration of the principles of the
invention and its practical application, and to enable one of
ordinary skill in the art to utilize the invention in various
embodiments and with various modifications as are suited to the
particular use contemplated. All such modifications and variations
are within the scope of the invention as determined by the appended
claims, as may be amended during the pendency of this application
for patent, and all equivalents thereof, when interpreted in
accordance with the breadth to which they are fairly, legally, and
equitably entitled.
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