Patent Application
20090044495
1. Field of the Invention
Embodiments of the present invention relate to packaging machines and, more particularly, to an automated packaging machine for filling containers with pills, and associated method.
2. Description of Related Art
Pharmaceutical medicines and associated packaging apparatus are typically subject to relatively strict consumer protection guidelines. For example, pills, capsules, and the like, must be produced and packaged in such a way as to at least meet the minimum sterility requirements mandated by federal regulations. In addition, the pills should be delivered into the packaging such that the contents accurately meet the claimed labeling “count”, i.e., such that each package includes exactly the predetermined number of pills. Notwithstanding the above, it is also desirable to package the product in a mass production operation to offset costs typically attributed to a labor intensive operation, in order to provide an economical product.
In the past, pill filling machines have been proposed that provide automated bottle counts by filling a hopper with pills and causing a plurality of the pills to be caught by a pill capturing device, such as an array of rotary slats. The rotary slats drop the captured pills into a plurality of bottles disposed in alignment with the dropping pills. The bottles are distributed along an endless conveyor belt that is timed to advance and stop the bottles according to the filling operation.
Some conventional pill capturing devices more particularly include a series of rotary slats each configured to receive, hold, and move a plurality of capsules or pills along a closed path. The rotary slats are typically discs fixed on a rotatable shaft and have a plurality of openings in the outer peripheral edge portion thereof for capturing individual pills. Accordingly, the closed path is arcuate and generally disposed between a pill hopper and discharge area above a conveyor belt. By the rotary action of the slats, the pills move in a direction normal to the conveyor belt. The pill capturing device then generally discharges the pills by rotating the slats, which move in correspondence with the closed path, such that the pills fall out of the respective openings at the filling station. The pills are often funneled through a chute that empties into a corresponding bottle.
The “count,” or number of pills in the bottle, is typically determined by positioning the bottles in the pill dropping zone for a predetermined time. The duration of the filling operation for each bottle corresponds to the number of openings in each slat that the machine is capable of delivering to the bottles per unit of time. The duration of the filling operation, speed of the rotary slats, and configuration of the pill capturing device, are thus used to calculate the count.
Unfortunately, if the pill capturing device fails to capture a pill in each and every cavity or receptacle of the slats, or if a pill should mistakenly be diverted away from a path toward the bottles, at least one of the bottles can be improperly filled. A conventional solution to this problem is to situate an operator adjacent to the slats to ensure that each receptacle is filled with a pill. If a pill is missing, the operator manually places a pill in the receptacle. However, such an approach involves additional labor costs and can be unsatisfactory for sterility purposes. In addition, the accuracy of the count of each bottle is largely determined by the operator and, as such, a fully and consistently-accurate counts cannot be guaranteed.
U.S. Pat. No. 6,185,901 to Aylward, which is incorporated herein by reference, provides an exemplary solution to this problem by way of a machine with a plurality of independently-driven rotary slats. The pills are allowed to fall into an exterior receptacle of each rotary slat and, in one embodiment, passed under a rotary brush, in an attempt to prevent two pills from being disposed in the same receptacle. A separate counting device is associated with each rotary slat for counting each pill as it falls from the slat into the container. A positive count is provided for each container and improperly-filled slats will not affect the total count for that container. If a particular container has a low count, the respective slat can be further rotated to fill the container. Because the slats are independently driven, the other slats can remain stationary to prevent overfilling. Thus, such a machine is capable of accomplishing an accurate filling of each bottle, but consistent filling of the exterior receptacles of each rotary slat may be difficult and may require additional provisions for assuring continuous filling of the receptacles in a reliable manner.
One alternative apparatus is a rotatable drum, as provided in U.S. Pat. No. 4,094,439 to List. The rotatable drum includes a plurality of parallel rows of throughgoing holes that constitute receptacles for dragees. The dragees enter the receptacles in the drum from the interior of the drum at an inner input location, exit to the exterior of the drum at an outer retrieval location, and are filled into bottles. An ordering device facilitates the entry of the dragees into the receptacles, and feeler blades engage the receptacles. If any of the receptacles in an axially extending row do not contain a dragee, one of the feeler blades actuates a bolt pusher, which prevents any of the dragees in the row from being deposited into the bottles. Instead, a solenoid and knockout bar empty the receptacles of the row. By preventing the bottles from being filled from partially-filled rows of receptacles, the apparatus prevents the different bottles from being filled at different rates. However, the additional mechanical components required for emptying the partially filled rows of apertures undesirably increase the complexity, cost, and likelihood of failure or inaccurate count of the apparatus. Additionally, emptying the partially filled rows slows the process of filling the bottles, since no pills are dispensed from those rows.
Accordingly, there is a need for a packaging apparatus which provides an accurate count for each container and operates at a high speed. The apparatus should require a minimum of operator intervention. Additionally, the apparatus should be cost effective, both in initial cost and maintenance costs.
The above and other needs are met by embodiments of the present invention which, according to one aspect, provides an automated packaging apparatus for depositing pills into a container. Such an apparatus comprises a rotary slat configured as a cylinder rotatable in a rotational direction about an axis extending longitudinally therethrough, wherein the cylinder comprises a radially outward portion and an opposing radially inward portion, and defines a plurality of pill apertures therein. Each pill aperture is adapted to receive a pill from a plurality of pills deposited into an interior space defined by the cylinder. The pills are received by the pill apertures, from the interior space, at a first angular position of the rotary slat. A negative pressure system is in fluid communication with the pill apertures of the rotary slat, wherein the negative pressure system is configured to apply a negative pressure to the pill apertures, so as to retain the pills therein, as the rotary slat rotates about the axis from the first angular position to a second angular position. A removal system is configured to interact with each of the pill apertures of the rotary slat, as the respective pill aperture is disposed at the second angular position, so as to remove the respective pill therefrom through the radially outward portion of the rotary slat. A collection system is disposed adjacent to the radially outward portion of the rotary slat, about the second angular position, and is configured to direct each pill removed from each respective pill aperture toward a container for deposition therein.
Another aspect of the present invention comprises a method of automatically depositing pills into a container. Such a method includes receiving a pill in each of a plurality of pill apertures defined by a rotary slat, wherein the rotary slat is configured as a cylinder rotatable about an axis extending longitudinally therethrough and comprises a radially outward portion and an opposing radially inward portion. The pills are provided from a plurality of pills deposited into an interior space of the cylinder, and are received by the pill apertures at a first angular position of the rotary slat. The rotary slat is rotated in a rotational direction about the axis, from a first angular position to a second angular position, while a negative pressure is applied to the pill apertures, so as to retain the pills within the pill apertures, as the rotary slat rotates in the rotational direction from the first angular position to the second angular position. The pills are removed from the pill apertures, at the second angular position of the rotary slat, through the radially outward portion of the rotary slat. Each pill removed from each respective pill aperture is then directed toward a container for deposition therein.
Thus, embodiments of the present invention include an automated packaging apparatus and associated method providing an accurate count of pills dispensed to each container. Such an apparatus requires a minimum of operator intervention, and can operate at a high speed. Additionally, such an apparatus is cost effective, both in initial cost and maintenance cost.
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, wherein:
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many 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. Like numbers refer to like elements throughout.
Embodiments of the present invention are generally directed to a pill handling apparatus 10, such as an automated packaging machine. Such a pill handling apparatus can be used for dispensing pills into containers, as discussed, for example, in U.S. Pat. No. 6,185,901 to Aylward, and in U.S. Pat. No. 6,401,429 to Aylward, the contents of which are incorporated herein by reference. In other embodiments, such a pill handling apparatus can be used for other handling operations, besides pill packaging, such as transporting pills during manufacture, inspection, or the like.
As illustrated in
The pill handling apparatus 10 includes a rotary slat 18 for receiving pills 12 and transporting the pills 12 to the receiving containers 16. The rotary slat 18 is generally configured as a cylinder defining a longitudinal axis therethrough, wherein the plurality of pills 12 is received within an interior space 20 defined by a radially inward portion 21A (i.e., an inner surface) of the cylinder. The radially inward portion 21A further defines receptacles or pill apertures 22 (wherein the terms “receptacle” and “aperture” are used interchangeably herein with respect to element 22) along one or more paths about the rotary slat 18. For example, the slat 18 is illustrated as having parallel paths of receptacles 22, with each path extending about the inner surface 21A perpendicularly to the longitudinal axis (i.e., about the inner circumference thereof). In some instances, the radially inward portion 21A of the rotary slat 18 can define adjacent continuous grooves or slots (see, e.g.,
As shown in
The rotary slat 18 may be engaged with and rotated by a drive arrangement or mechanism 120 to transport the pills 12 from the interior space 20 to the containers 16. The rotary slat 18 rotates in a first direction 19 defining an arcuate delivery path from a pill capture or first angular position 23A to a release or second angular position 23B, where the pills 12 are released. The release position 23B is generally more than about 180 degrees away from the pill capture position 23A, but nonetheless above a horizontal plane extending through the longitudinal axis (whereas the pill capture position 23A is below the horizontal plane). In one embodiment, the first angular position 23A may be, for instance, about the “six o'clock” position (i.e., between about “four o'clock” and about “eight o'clock”), while the second angular position 23B may be, for instance, about the “two o'clock” position. The drive arrangement may be configured, for example, to engage an outer surface or an end surface of the rotary slat 18 by friction or geared engagement to turn the rotary slat 18 in the first direction 19.
The rotary slat 18 is configured such that each pill aperture 22 extends from the radially inner portion 21A (i.e., inner surface) to the outer radial portion 21B (i.e., outer surface) of the cylinder. Each pill aperture 22 is thus configured such that the pills 12 can pass therethrough. The pill apertures 22 therefore include several aspects for retaining the pills 12 therein, as the pills 12 are transported from the first angular position 23A to the second angular position 23B with respect to the rotary slat 18 rotating in the rotational direction 19 (i.e., clockwise) about the longitudinal axis thereof. In one instance, each pill aperture 22 may include a retaining flange or lip 100 about the radially inward portion 21A of the rotary slat 18, and about the leading edge of the pill aperture 22 with respect to the rotational direction 19. The retaining flange 100 at least partially facilitates retention of the pill 12 within the respective pill aperture 22, as the pill 12 is deposited therein from the interior space 20.
The rotary slat 18 may be formed as an integral, single-piece component. In such instances, a suitable forming device such as, for example, a laser sintering device may be implemented to form the rotary slat 18. In other instances, the rotary slat 18 may be cast, machined, molded, or otherwise formed. A variety of materials can be used for the construction of the rotary slat 18 including, but not limited to, metals, metal alloys, and polymers. In some instances, the rotary slat 18 is formed of a durable, low friction material that is cost effective for manufacture, such as a compound comprising acrylonitrile-butadiene-sytrene and polytetrafluoroethylene. Depending on the type of pills 12 fed by the rotary slat 18, it may also be important that the material of the rotary slat 18 does not chemically affect the pills 12. Other components of the pill handling apparatus 10 can be made of the same or different materials.
Further, in order to prevent the pills 12 from exiting the pill apertures 22 through the radially outward portion 21B of the rotary slat 18, as the pills 12 are transported from a first angular position 23A to a second angular position 23B, the radially outward portion 21B of the rotary slat 18 may be at least partially covered by a shroud member 30 disposed adjacent thereto. That is, the shroud member 30 is disposed adjacent to the rotary slat 18, at least between about the first angular position 23A and about the second angular position 23B, so as to cover the pill apertures 22 from the radially outward portion 21B of the rotary slat 18, while allowing the rotary slat 18 to rotate with respect thereto in the rotational direction 19.
A controller 46 may be configured to control the operation of the drive arrangement such that the rotary slat 18 can be rotated at various speeds, if desired or appropriate. For example, the rotary slat 18 can be rotated at a fast speed during the initial portion of the pill filling operation, until a predetermined number of the pills 12 is delivered to the respective container 16, and subsequently rotated at a slower speed to finish the filling operation and to prevent under-filling or over-filling of the container 16. Additionally, the controller 46 can alternately accelerate and decelerate the rotary slat 18 to cause a jerking or vibratory motion for agitating the pills 12. Such agitation of the pills 12 can be useful in encouraging the pills 12 to become seated in the pill receptacles 22.
In some embodiments, a negative pressure system or vacuum assembly 90 may be disposed in fluid communication with the rotary slat 18 to apply suction, or draw air into, the receptacles 22 of the rotary slat 18 through, for example, appropriate holes defined by the shroud member 30 so as to act upon pills 12 to be received from the interior space 20 or retained within the receptacles 22. In particular, the vacuum assembly 90 may include the shroud member 30 disposed adjacent to the rotary slat 18 so as to extend at least partially about the radially outward portion 21B thereof. Air may be drawn from the pill apertures 22 and through the shroud member 30 by a fan, pump, or other appropriate low pressure source through a vacuum chamber 32 associated with the shroud member 30, whereby the receptacles 22 can be affected by suction applied via the shroud member 30. As such, the receptacles 22 temporarily disposed between the first angular position 23A and the second angular position 23B are temporarily disposed in fluid communication with the suction applied via the shroud member 30 such that, as air is drawn from the vacuum chamber 32, suction is created in the receptacles 22. The disposition of the receptacles 22, in this regard, is referred to herein as “temporary” because the rotary slat 18 is generally being rotated when the pill handling apparatus 10 is used. Thus, the vacuum assembly 90 can selectively draw air into or apply suction to the receptacles 22 according to the rotational position of the rotary slat 18 so that the pills 12 are urged into the receptacles 22 at the first angular position (e.g., the “capture” position 23A of the rotary slat 18) and released from the receptacles 22 at the second angular position (e.g., the release position 23B for dispensing the pills 12 into the containers 16).
Thus, pills 12 deposited into the interior space 20 of the cylindrical rotary slat 18 are urged toward receipt and capture by the receptacles 22 because of the air currents and pressure differentials present at the receptacles 22 due to the suction imparted by the vacuum assembly 90 via the shroud member 30. In some cases, the pills 12, once seated in the receptacles 22, may at least temporarily partially or entirely block the holes defined by the shroud member 30. Thus, these descriptions relate to configurations wherein each seated pill completely seals the receiving receptacle to prevent further air flow, configurations wherein each seated pill partially seals the receiving receptacle to limit further air flow, and configurations wherein air flow is permitted without significant reduction by a pill seated in a receptacle. Accordingly, the vacuum assembly 90 may also serve to clean the pills 12, but may also allow pill fragments or other particles to fall from the receptacles 22 and back into the interior space 20 of the rotary slat 18. Such a fragment/particle removal process is further facilitated by the respective dispositions of the first and second angular positions 23A, 23B (i.e., transporting the pills through the “12 o'clock” position allows the fragments/particles the opportunity to fall from the receptacles 22). As a receptacle arrives at the release or second angular position 23B, the vacuum chamber 32 ends and the receptacles 22 associated therewith lose fluid communication with the shroud member 30. About the second angular position 23B, the retaining flange 100 prevents the pill 12 from exiting the rotary slat 18 through the radially inward portion 21A thereof. That is, as each receptacle 22 reaches the release or second angular position 23B, the receptacle 22 is rotated beyond the shroud member 30 so that the pill 12 is no longer held in the receptacle 22 by suction, but rather by the retaining flange 100. One skilled in the art will appreciate, however, that other configurations of vacuum assemblies 90 can be used to provide the desired suction for controlling the seating of the pills 12 in the rotary slat 18. Also, while the illustrated vacuum assembly 90 is used to maintain the pills 12 in the receptacles 22 between the capture and release positions 23A, 23B, and the retaining flange 100 used to maintain the pills 12 within the receptacles 22 about the release position 23B, a shroud or cover can be additionally or alternatively be provided about the radially inward portion 21A of the cylindrical rotary slat 18 for preventing the release of the pills 12 from the receptacles 22 through either the radially inward portion 21A or the radially outward portion 21B.
In some embodiments of the present invention, a removal system 95, such as a positive pressure or blower assembly, or other suitable ejection mechanism, can be disposed in fluid communication with each receptacle or pill aperture 22 for removing the respective pills 12 therefrom through the radially outward portion 21B of the rotary slat 18. In order to facilitate the removal of the pills 12 from the receptacles 22, the shroud member 30 is configured to define a dispensing aperture 160 about the second angular position 23B (with the dispensing aperture 160 being configured to allow the pill 12 to pass therethrough).
As shown in
In some instances, the removal system 95 may be configured to at least partially determine the filling of the containers 16. That is, the pills 12 will be extracted or removed from the pill apertures 22 as long as the removal system 95 is “on” (i.e., as long as air is being blown into the first and second capillaries 150A, 150B. In such instances, even though a container 16 is not being filled and the removal system is “off,” the rotary slat 18 and the vacuum system 90 may be continually rotated such that the rotary slat 18 remains primed with pills 12 in the receptacles 22 in preparation for filling the next container 16. The external removal system 95 further allows for interchangeability of the rotary slat 18 without having to reconfigure or adjust the capillaries 150A, 150B (i.e., each rotary slat 18 includes an appropriately configured second capillary 150B for cooperating with the first capillary 150A). Servicing and maintenance of the apparatus 10 may also be facilitated by such a configuration of the removal system 95. However, one skilled in the art will also appreciate that the removal system 95 may be configured in different manners. For example, the removal system 95 may, in some instances, be disposed within the interior space 20 of the rotary slat 18 and configured to blow air outwardly through the second capillary 150B (the first capillary 150A would not be necessary) to accomplish a similar effect.
Once the pills 12 are removed from the rotary slat 18 through the radially outward portion thereof and through the dispensing aperture 160 defined by the shroud member 30, the pills 12 are collected by a collection system 60 and directed toward the container(s) 16 for deposition therein. More particularly, the collection system 60 may comprise one or more chutes 62 disposed adjacent to the release or second angular position 23B of the rotary slat 18 (and adjacent to the dispensing aperture 160) for receiving the pills 12 and guiding the pills 12 from the rotary slat 18 to a container 16. Accordingly, as a receptacle 22 having a pill 12 therein arrives at the release position 23B, the pill 12 is removed from the receptacle 22 and is collected by a chute 62 through the dispensing aperture 160. The chutes 62 may be comprised of, for example, an acetal or Delrin™ polymer, available from DuPont.
The number of pills 12 delivered to each container 16 must also be determined. In this regard, a counting device or counter device 200 can be associated with the rotary slat 18 or the chute(s) 62 of the collection system 60 prior to the pills 12 being deposited into the container 16. For example, one or more counting devices 200 can be positioned adjacent, above, below, or within a chute 62 so that any pill 12 which travels through the chute 62 will be detected by the counting device 200. One exemplary counting device 200 includes an infrared light source and a light receiver positioned substantially opposite the light source across a central passage (i.e., the chute 62). The light source generates a light beam that is detected by the opposing light receiver. When the light beam is interrupted by a falling pill 12, the light receiver transmits a signal which increases the count in the controller 46. Thus, the number of interruptions corresponds to the number of pills 12 delivered into a particular container 16.
In some embodiments, the controller 46 may also be configured to control the quantity of pills 12 provided in the reservoir 14. For example, a level sensor can detect the quantity of pills 12 in the reservoir 14. The quantity may be determined optically, by weight, or otherwise. The level sensor communicates a corresponding value or signal to the controller 46. When the controller 46 detects that the level of pills 12 in the reservoir 14 is below the desired level, the controller 46 can open a reservoir gate that controls the passage of pills 12 from a bulk bin to the reservoir 14, thereby maintaining a desired number of pills 12 in the reservoir 14. The desired level of pills 12 in the reservoir 14 can be adjusted to optimize the seating of pills 12 in the receptacles 22 of the rotary slat 18 and to prevent wearing or breaking of the pills 12 caused by overfilling of the reservoir 14.
In some instances, a pill inspection device (not shown) may also be implemented, wherein the counting device 200 may be a separate and different component, or may be incorporated with the pill inspection device. For example, the counting device(s) and/or inspection device(s) can be configured to detect the pills by counting and/or inspecting the pills. In some cases, the inspection device may be, for example, an optical imaging device, such as a camera, configured to monitor the chute(s) 62 for pills 12 passing therethrough by detecting an image of each pill to determine the size, shape, and/or other characteristics of the pill. Thus, the inspection device can be configured to determine the presence of the pills 12 in the chute(s) 62 (i.e., as a counting device) and/or determine a characteristic of the pills 12, such as whether the pills are broken or otherwise defective. If provided, the inspection device is disposed in communication with the controller 46, e.g., so that the controller can use the inspection device to determine, for example, if a chute 62 is blocked.
In one embodiment, the container 16 may be brought into position under the chute(s) 62 by a conveyor device 70 or other suitable container-movement system, as will be appreciated by one skilled in the art, wherein the container 16 may be appropriately placed, for example, by mechanical stops or any number of placement arrangements. Since the pills 12 are dispensed from the rotary slat 18 in parallel to the longitudinal axis thereof, the conveyor device 70 may be configured to move the container 16 into coincidence with the collection system 60 (i.e., presuming that the collection system 60 directs the pills 12 directly downward from the respective apertures 22) along a horizontal path substantially perpendicular to the axis. In such a manner, a plurality of pill packaging apparatuses 10, represented by a corresponding plurality of rotary slats 18 (i.e., as shown in
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
This application claims the benefit of U.S. Provisional Application No. 60/954,969, filed Aug. 9, 2007, which is incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60954969 | Aug 2007 | US |
