The present invention is directed to a bottle or vial delivery system and process. More particularly, the preferred embodiment of the present invention relates to a pneumatic bottle delivery system for transporting pharmaceutical bottles from a main shared storage “hopper” or storage bins in an isolated area to several individual labelers mounted directly above the conveyor production line.
The preferred embodiment of the present invention allows for a higher volume of bottle transport while increasing storage volume capacity of the traditional bottle storage hoppers which reduces the frequency of manual replenishment of the bottle storage area (e.g., lower bottle replenishment intervals).
The present invention also relates to an improved method and system for distributing bottles to the desired locations, for example, distributing the bottles to individual labelers. In the preferred embodiment, this distribution method and system can be controlled at varying rates based on the required production output.
In one embodiment of the present invention, a pneumatic bottle delivery system transports pharmaceutical bottles from a main storage hopper in an isolated area to several individual labelers mounted directly above the conveyor production line.
In one embodiment, for example, three large bottle hoppers are dedicated to this transport system. In this example, each hopper has an individual bottle orientation device and an inlet air pipe adjacent to the bin that enables distribution of the bottles to sub-sets of three to four labelers—supporting a total number of twelve.
In the preferred embodiment, a network of sensors and control gates detect and distribute the flow of bottles to individual labelers dependent upon the bottle queue at each labeler. Accordingly, the present invention provides the ability to replenish bottles from a separate storage location and feed multiple labelers simultaneously. More specifically, the preferred embodiment of the system provides the ability to utilize the feed process from one storage hopper to distribute bottles to several labelers, gaining the ability to shift distribution flow to labelers with the greatest replenishment need.
With the development of this transport system, greater storage volumes were created with correspondingly reduced manual bottle replenishment intervals. In the example embodiment discussed, bottle replenishment can be reduced to once or twice daily. This feature enables greater system flexibility under scenarios of higher production rates or movement of bottles.
The following detailed description of the example embodiments refers to the accompanying figures that form a part thereof. The detailed description provides explanations by way of exemplary embodiments. It is to be understood that other embodiments may be used having mechanical and electrical changes that incorporate the scope of the present invention without departing from the spirit of the invention.
In addition to the features mentioned above, other aspects of the present invention will be readily apparent from the following descriptions of the drawings and exemplary embodiments, wherein like reference numerals across the several views refer to identical or equivalent features, and wherein:
The pill bottles then tumble into the orientation device 20 where they are all situated with the openings 22 facing upward and are dropped into an inlet tube 24 for distribution to the labelers.
The bottles are held in the inlet tube until a signal is received to replenish a specific labeler served by that hopper. For example, in one embodiment, each hopper has a dedicated pneumatic tube 26 feeding a sub-set of three to four labelers. When the queue is short at a labeler, the bottles in the staging area inlet tube are released into the adjacent high pressure pneumatic line for delivery.
At approximately the midpoint between the storage hopper and the labelers, control gates 28 actuate a flexible portion of the high pressure line to direct bottles to different tubes 30 that travel to a destination labeler.
In the embodiment shown in
In the preferred embodiment, a network of sensors and control gates detect and distribute the flow of bottles to individual labelers dependent upon the bottle queue at each labeler. Accordingly, the present invention provides the ability to replenish bottles from a separate storage location and feed multiple labelers simultaneously. More specifically, the preferred embodiment of the system provides the ability to utilize the feed process from one storage hopper to distribute bottles to several labelers, gaining the ability to shift distribution flow to labelers with the greatest replenishment need. For example, if a sensor located at a first labeler determines that the bottle queue is short, the control system is programmed to generate a signal to the control gate to deliver more bottles to the first labeler. In the preferred embodiment, the system can deliver a predetermined number of bottles to the first labeler by controlling the system.
For example, for each labeler, the bottle tube holding the bottles has three photo-eye (photoelectric) sensors (high, middle, and low). The level of vials in the tube is monitored by these sensors, which are connected to a control program. When the “high” PE does not see a vial, the control program will release a small number of vials from the blower. When either the “medium” or “low” PEs does not see a vial then the control program will release a larger number of vials. In one embodiment, the control system is a “soft-plc” that serves as a translation layer between the hardware and software control system with some logic capabilities. In the preferred embodiment, the blower is not constant and operates on-demand depending on the vial levels at the labeler.
In one example embodiment, each blower is connected to a set of labelers. Blower 1 is connected to labelers 3, 6 and 9. Blower 2 is connected to labelers 1, 4, 7 and 11. Blower 3 is connected to labelers 2, 5, 8 and 10. Swing gates are used to divert the vials to the proper labeler. For example, there will be a swing gate before labeler 3 that can swing from labeler 3 towards labelers 6 and 9, and another one before labeler 6 that can swing from labeler 6 to labeler 9. By default, the swing gates will be open towards the nearest labeler (labeler 3 for example). This way, higher pressure may be obtained for pushing the vials. If the vials need to get to a farther labeler (labeler 6 for example), the swing gate will preferably move to that labeler's position sometime after the blower releases the vials (e.g., 0.8 second after releasing vials).
While certain embodiments of the present invention are described in detail above, the scope of the invention is not to be considered limited by such disclosure, and modifications are possible without departing from the spirit of the invention. For example, the method and system can be used for transporting other types of bottles other than pill bottles or may be used to transport other types of objects from storage locations to other desired locations.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/720,070, filed on Oct. 30, 2012, titled Pneumatic Bottle Delivery System, which is incorporated herein by reference.
Number | Date | Country | |
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61720070 | Oct 2012 | US |