Patent Application
20120177473
This invention relates generally to materials handling, and more particularly to pharmaceutical prescription handling.
In mail order, central fill and large retail pharmacies, prescription drugs are dispensed in a high volume. For such services, it is known to use an automatic pill dispensing system to carry out the dispensing of the prescription drugs automatically at a rapid rate.
In some high volume systems, separate conveyors and vial carriers may be used to convey vials to and from the automated dispensing apparatus. The vial carriers are typically employed to prevent a vial from toppling over as it is conveyed at high speeds. In many high volume dispensing operations, vials of the same size are filled consecutively (in many cases with the same drug), so carriers of similar size are also used. The vials may be labeled prior to or after filling and/or capping.
A known automatic pill dispensing system is described in U.S. Pat. No. 6,971,541 to Williams et al. This system has the capacity to select an appropriate vial, label the vial, fill the vial with a desired quantity of a selected pharmaceutical tablet, apply a cap to the filled vial, and convey the labeled, filled, capped vial to an offloading station for retrieval. The system has a large number of different bins, or cells, each of which is filled with a specific drug. Two robotic arms transfer each vial between stations for accomplishing many of the various above-mentioned tasks. Counting and dispensing from the cells is carried out with air and suction applied to the cell to agitate pills and direct them to a dispensing outlet, where they are counted as they are dispensed. An updated version of this system is illustrated and described in, for example, U.S. Patent Publication No. 2009-0178464, the disclosure of which is hereby incorporated herein in its entirety. In this later version of the system, only one robotic arm is incorporated, and the vial selection and labeling tasks are performed before the robotic arm picks up the vial. In each instance, the air/suction-based dispensing technique can provide accurate counting and dispensing at high speeds.
An alternative high volume dispensing system that capitalizes on advantages inherent in the Williams et al. type automated dispensing machine is discussed in U.S. Provisional Patent Application No. 61/353,510, filed Jun. 10, 2010, the disclosure of which is hereby incorporated herein in its entirety. This system employs a version of the Williams et al. automated dispensing machine that has been modified to receive empty containers (vials or bottles) from a conveyor, fill the containers according to instructions from a controller, and return the filled containers to the conveyor for further processing.
The machine may be exposed to different sizes and configurations of containers. It would be desirable to provide a gripping assembly that can accommodate containers of different sizes and configurations.
As a first aspect, embodiments of the present invention are directed to a gripper unit. The gripper unit comprises a gripper body and first and second arcuate fingers that are pivotally mounted on the gripper body for rotation about parallel first and second axes. The first and second fingers have inner surfaces that face each other, each of the inner surfaces including longitudinal grooves. A gripper assembly of this configuration may be particularly suited for gripping bottles of different sizes and configurations, particularly those that have a lip or ridge on the bottle neck.
As a second aspect, embodiments of the present invention are directed to a robotic arm assembly, comprising: a vertical rail; a carriage slidably mounted on the rail for movement along a vertical axis defined by the rail; and a gripper unit revolvably mounted on the carriage. The gripper unit comprises a gripper body and first and second arcuate fingers that are pivotally mounted on the gripper body for rotation about first and second axes that are parallel to the vertical axis. The first and second fingers have inner surfaces that face each other, each of the inner surfaces including longitudinal grooves.
The present invention will now be described more fully hereinafter, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numbers refer to like elements throughout. Thicknesses and dimensions of some components may be exaggerated for clarity.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein the expression “and/or” includes any and all combinations of one or more of the associated listed items.
In addition, spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
As used herein, the term “forward” and derivatives thereof refer to the general direction vial carriers and vials travel as they move from station to station; this term is intended to be synonymous with the term “downstream”, which is often used in manufacturing environments to indicate that certain material being acted upon is farther along in the manufacturing process than other material. Conversely, the terms “rearward” and “upstream” and derivatives thereof refer to the directions opposite, respectively, the forward and downstream directions.
Well-known functions or constructions may not be described in detail for brevity and/or clarity.
An exemplary automated pharmaceutical dispensing system is illustrated in
The conveyor unit 70 includes a line conveyor 71 that is positioned to convey a series of pucks 72. Each puck 72 is sized and configured to receive a pharmaceutical vial or bottle in a central cavity 74. As used herein, the term “vial” is intended to mean an open-ended container typically used for pharmaceuticals, and is intended to encompass vials, bottles, jars, and the like. The cavity 74 of the puck 72 is typically slightly larger than the vial, which facilitates insertion of the vial in the puck 72, and is typically round. In the illustrated embodiment, pucks 72 are employed to reduce the risk of the vial or bottle tipping during conveying.
Also, in this embodiment, the pucks 72 include an RFID tag (located in a recess in the underside of the puck 72) which indicates a prescription number for the prescription to be filled by the dispensing machine 40 or another indicator of the drug and number of tablets to be dispensed, which can be used to indicate to the system 40 which pharmaceutical is to be dispensed into the vial. As used herein, an “RFID tag” is an object applied to or incorporated into a component for the purpose of identification and tracking using radio waves. Some RFID tags can be read from several meters away and beyond the line of sight of the reader. Many RFID tags contain at least two parts. One is an integrated circuit for storing and processing information, modulating and demodulating a radio-frequency (RF) signal, and other specialized functions. The second is an antenna for receiving and transmitting the signal. There are generally three types of RFID tags: active RFID tags, which contain a battery and can transmit signals autonomously, passive RFID tags, which have no battery and require an external source to provoke signal transmission, and battery assisted passive (BAP) which require an external source to wake up but have significant higher forward link capability providing great read range. Any of these may be used in connection with the present invention. Exemplary RFID tags and readers are disclosed in U.S. Pat. No. 6,317,648 to Sleep et al., the disclosure of which is hereby incorporated herein in its entirety.
Generally, operation of the system 20 commences with pucks containing empty vials being conveyed along a path P from one end of the conveyor unit 70 to a position adjacent the transition platform assembly 80 (
Those skilled in this art will appreciate that the conveyor 70 may take any number of forms, including belt conveyors, rollers, slide conveyors, and combinations thereof. In some embodiments, the conveyor 70 may even take the form of a robotic aim that positions the pucks 72 on the diverter platform 80. Also, in some embodiments, the conveyor unit 70 may be endless (e.g., it may follow an oval path), such that pucks 72 are emptied of their filled vials and automatically returned to a starting point to receive another empty vial for another dispensing operation.
Referring now to
Two substantially identical diverter units 84a, 84b are mounted over the conveyor 71, with diverter unit 84a being positioned slightly upstream of the diverter unit 84b. Two substantially identical return units 88a, 88b are also mounted over the conveyor 71, with the return unit 88a being positioned in alignment with the diverter unit 84a and the return unit 88b being positioned in alignment with the diverter unit 84b. These are discussed separately below.
Each diverter unit 84a, 84b includes a horizontally-disposed guide 85 that extends over the conveyor 70, diverter rods 86 that extend from and retract into the guide 85, and a vertically-disposed paddle 87 that is suspended from the rods 86, and a pneumatic actuator (not shown) that acts to retract and extend the rods 86. When the rods 86 are retracted into the guide 85, the paddle 87 is positioned across the conveyor 71 from the transition platform assembly 80. Each paddle 87 is positioned to be generally aligned with a respective recess 82 of the aligner panel 81.
Each of the return units 88a, 88b includes a guide 89, rods 90, and a pneumatic actuator (not shown) similar to the guides 85, rods 86 and actuator discussed above. An L-shaped, vertically-disposed sweep arm 91 is mounted on the end of each set of rods 90 (with the sweep arm 91 of the return unit 88a being a mirror image of the sweep arm 91 of the return unit 88b). When the rods 90 are extended from the guides 89 and across the conveyor 70, the sweep arm 91 of each return unit 88a, 88b is positioned such that one of the recesses 82 is between the sweep arm 91 and the conveyor 70. In this embodiment, each of the sweep arms 91 is offset from the paddle 87 of its corresponding diverter unit 84a, 84b and positioned such that its lower segment 91a can pass beneath the paddle 87 and its vertical segment 91b can pass beside the paddle 87. In other embodiments, the sweep arms are not offset to go beneath or to the sides of the paddles or to the side, but rather when fully retracted they stop short from interacting with the paddles. Also, the shape of the sweep arms 91 enables them to avoid interference with the gripper assembly 100 as it approaches the transition platform assembly 80.
In the illustrated embodiment, the automated dispensing machine 40 is similar to that described in U.S. Patent Publication No. 2009-0178464, supra, with the vial dispensing, labeling, capping and offloading stations removed. The gripper assembly 100, which includes the robotic arm 102 and gripper fingers 104a, 104b mounted thereon, is mounted on a carriage 106 that can translate vertically on a rail 108 and can revolve around the carriage 106. The rail 108 is mounted for translation on a pair of horizontal rails (not shown) that enable the arm 102 to be transported to different positions within the automated dispensing machine 40. The automated dispensing machine 40 includes a large number of dispensing bins, or cells, 42, each of which contains a bulk supply of a pharmaceutical (typically pills or tablets). Typically, different pharmaceuticals are contained in different bins 42. Each of the bins 42 is configured to dispense a given pharmaceutical into a vial held by the gripper fingers 104. Dispensing is achieved by directing air flow within a bin 42 that forces individual tablets into and out of a dispensing outlet into a waiting vial. The tablets are singulated and counted during dispensing. Further discussion of the details of the dispensing and counting operations can be found in, e.g., U.S. Pat. No. 6,971,541 to Williams and U.S. patent application Ser. Nos. 12/492,933 and 12/473,757, the disclosure of each of which is hereby incorporated herein in its entirety. Those skilled in this art will recognize that other configurations of automated pharmacy machines, such as those shown in U.S. Pat. No. 7,289,879, may also be employed.
Referring now to
The gripper fingers 104a, 104b are mirror images of each other. Each includes a gear portion 212 and an arcuate gripping portion 216. The gear portion 212 has teeth 214 that mate with the helical ridges of the worm gear 208. The gear portion 212 also includes an aperture 213 that receives a post 220 mounted on the base 200. The posts 220 define parallel vertical axes around which the gripper fingers 104a, 104b can rotate.
The gripping portion 216 of each of the gripper fingers 104a, 104b is generally semicircular. Typically, the gripping portion 216 has a height of between about 0.25 and 0.50 inches. A longitudinal v-profiled groove 218 is present on the inside surface 217 of each of the gripping portions 216, such that the groove 218 of the gripper finger 104a faces the groove 218 of the gripper finger 104b and is at approximately the same elevation. The groove 218 defines an arc of between about 90 and 150 degrees, has a radius of curvature of between about 0.70 and 1.0, and has a height of between about 0.05 and 0.125 inches.
Referring to
The system 20 also includes a series of sensors connected with the controller 200 for detecting the presence of objects within the system 20. Sensors 120, 122 are positioned on the transition platform assembly 80 to detect the presence of a puck 72 in a respective recess 82. Sensors 124, 126 are positioned on the transition platform assembly 80 to detect the presence of a vial within a puck 72 as the puck 72 resides in a respective recess 82. A sensor 128 is positioned on the frame of the automated dispensing machine 40 to detect the presence of the gripping assembly 100 above the base plate cover 76. Sensors 132, 134 are mounted near the conveyor 71 to detect the presence of a puck in position to be diverted by one of the diverter units 84a, 84b.
Operation of the system 20 commences with a puck 72 on the conveyor 71 upstream of the transition platform assembly 80 receiving a vial V of the proper size for a particular prescription. Depending on the arrangement of the system 20, the vial V may be selected based on the reading of the RFID tag on the puck 72, or may be part of a lengthy “run” of prescriptions using the same size vial. The vial V may or may not be labeled at this point in the operations. Also, the vial V may be manually inserted into the puck 72 or may be inserted automatically (e.g., with a robotic arm, a pick-and-place device, or a vial dispensing apparatus, which may in some embodiments include labeling capability).
The conveyor 70 then conveys the puck 72 and vial V downstream (see Block 300 of
As the puck 72 and vial V reach the transition platform assembly 80 and the sensor 120, 122 confirms the continued absence of a puck 72 in one of the recess 82, the controller 200 selects the appropriate diverter unit 84a, 84b to divert the puck 72 from the conveyor 71 and signals the selected diverter unit to divert the puck 72 and vial V. Actuation of the diverter unit 84a, 84b is initiated by one of the sensors 132, 134, which detects the presence of the puck 72 in front of the respective paddle 87 of a diverter unit 84a, 84b. Once the puck 72 is detected by the sensor 132, 134, the controller 200 actuates the diverter unit 84a, 84b to be used to divert the puck 72. In some embodiments, the controller 200 selects the diverter unit 84b (which is farther downstream) as a default unless it already houses a puck 72.
When the selected diverter unit 84a, 84b (illustrated as diverter unit 84a in
In some embodiments, it may be particularly advantageous for the puck 72 to be positioned within the footprint of the machine 40. For example, if, as is the case with the illustrated system, the puck 72 is diverted completely from the conveyor 71 as the vial is being filled by the automated dispensing machine 40, then the automated dispensing machine 40 may be oriented in any orientation that is considered to be desirable or advantageous. In certain embodiments, the ability to align the automated dispensing machine 40 to be generally perpendicular to the direction of conveyor travel may be advantageous, as it may enable the density of automated dispensing machines 40 servicing the same conveyor to be increased and/or maximized.
Once the puck 72 and vial V are in place, the sensors 120, 122 and 124, 126 detect their presence, and the RFID sensor 77 reads the RFID tag on the puck 72. Sensing of the RFID tag initiates a fill request for the automated pharmacy machine 40 via the controller 200. The RFID tag may correspond to a particular prescription stored in the database of the controller 200, or may include the prescription information itself. Detection of the RFID tag indicates to the controller 200 the identity and number of pharmaceutical tablets that are to be dispensed into the vial V.
The controller 200 signals the gripper assembly 100 to approach the transition platform assembly 80. The gripper assembly 100 approaches the container with the fingers 104a, 104b spread open. Once the gripper assembly 100 is in position, the controller 200 activates the motor 204, which rotates the shaft 206 and worm gear 208. Rotation of the worm gear 208 rotates the fingers 104a, 104b about their respective posts 220, thereby forcing the fingers 104a, 104b toward each other to grasp the container.
One issue that can arise with the gripping of containers is their different sizes and configurations. Pharmaceutical vials are typically largely cylindrical, with a radially-extending thread or lip that protrudes from the outer surface for cap securing. Such vials provide a configuration that is relatively straightforward for the gripper fingers 104a, 104, as the fingers 104a, 104b can grasp the vial on the cylindrical surface below the lip, with the lip providing a “backstop” that prevents the vial from slipping through the grasping fingers. Typically, pharmaceutical bottles are formed with a thicker body and a narrow neck. As is the case with a vial, the neck will ordinarily include a protruding thread or lip for cap securing. However, some bottles have relatively little room between the top of the body and the bottom of the lip and/or threads, such that there is insufficient room for gripper fingers to fit below the lip
The gripper fingers 104a, 104b can address this issue. The lip of the bottle (which typically extends from the bottle neck between about 1.55 and 1.60 inches and is typically between about 0.04 and 0.12 inches in height) can fit within the grooves 218 of the finger portions 216. As such, the gripper fingers 104a, 104b can securely grip the bottle (including providing support underneath the lip to prevent slippage) as it is conveyed through the operations described below. The grooves 218 can be used as a locating or gripping feature for the bottle. As the gripper fingers 104a, 104b close around the lip of a bottle, based on the dimensions the grooves 218 can locate or grip the fingers 104a, 104b around that feature. The vial or bottle is centered between the gripper fingers 104a, 104b with a dual V-groove design. When closed, the gripper fingers 104a, 104b can accommodate vials between 1.0 and 2.25 inches in diameter.
As an initial operation, the gripper assembly 100 moves to the puck 72 and vial V and grasps the vial with the fingers 104 (
After the positions of the vial and puck 72 have been adjusted and the RFID tag has been detected, the controller 200 signals the gripper assembly 100 to lift the vial V straight up from the cavity 74 of the puck 72 (so as not to disturb the adjusted position of the puck 72)(see
Once the vial V has been filled in the automated pharmacy machine 40, the controller 200 signals the gripping assembly 100 to return the filled vial V to a position above the puck 72 (Block 340 of
After the vial V has been returned to the puck 72 (and after correct filling is confirmed by the controller 200), the controller 200 activates the return unit 88a, 88b corresponding to the diverter unit 84a, 84b used earlier to divert the puck 72 and vial V (illustrated as return unit 88a in
Actuation of the return unit 88a, 88b causes the rods 90 to retract within the guide 89, thereby drawing the sweep arm 91 toward the conveyor 70 (Block 350 of
Those skilled in this art will appreciate that the diverter unit 84b and the return unit 88b operate in the same manner as the diverter unit 84a and the return unit 88a to divert carriers and vials to the recess 82 and return them to the conveyor 70, but do so along a non-coincident, substantially parallel path P2.
Those skilled in this art will appreciate that the system 20 may be embodied in other forms. For example, the diverter units 84a, 84b may include any variety of diverting member as a substitute for the paddles 87, and/or may include other means for extending and retracting the diverting members. Similarly, the return units 88a, 88b may include alternative return members to replace the sweep arms 91, and/or may include other means for extending and retracting the return members.
In addition, although the pucks 72 represent one embodiment of vial carrier that is suitable for use with this invention, other vial carriers of different shapes and sizes may also be employed. In some embodiments, the pucks 72 may lack an RFID tag, such that the sequence of prescription dispensing is retained in the controller itself, or the pucks 72 may include a different type of identifying indicia, such as a bar code.
It should also be apparent to those of skill in this art that the system 20 may be constructed by retrofitting an existing automated pharmacy machine 40. For example, an automated pharmacy machine such as that described in U.S. Patent Publication No. 2009-0178464, supra, may in some embodiments be modified by removing the vial dispensing, labeling, and capping stations. These system components may be replaced with additional dispensing cells, and/or a number of cells may be omitted to allow mounting of the transition platform assembly 80.
Also, the system 20 may be employed in a stand-alone fashion, with all pucks 72 and vials V being filled by the system 20, or the system 20 may be part of a larger high-volume filling operation. In such an operation, pucks and vials to be filled by the system 20 may be diverted onto or toward the conveyor unit 70 from a main line conveyor or the like that also conveys other pucks and vials to other dispensing apparatus. In other embodiments, the conveyor unit may be routed through the automated pharmacy machine 40.
Further, the adjustment maneuver performed with the gripper assembly 100 may be performed in other ways. For example, the gripper assembly 100 may simply contact the vial or puck while adjusting its position rather than actually grasping the vial, with that the controller 200 recording the position accordingly. The action of forcing the vial downwardly may be omitted in some embodiments.
Moreover, in some embodiments the automated pharmacy machine 40 may include a vial dispensing station and a vial labeling station that select a particular vial and label it prior to pharmaceutical tablets being dispensed into the vial. In such a system, the puck or other carrier can be conveyed without a vial to the transition platform assembly 80, where it can receive a filled, labeled vial. The filled, labeled vial and puck can then be returned to the conveyor 71 with one of the return units 88a, 88b for subsequent processing.
In addition, those of skill in this art will appreciate that the gripper assembly 100 may be suitable for use in other environments. For example, other automated materials handling operations, particularly those in which bottles are being handled, may benefit from the use of gripper assemblies of the present invention. Other potential objects that may be acted upon by such gripper assemblies include other varieties of containers, toys, tools, and the like.
The foregoing embodiments are illustrative of the present invention, and are not to be construed as limiting thereof. Although exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.
