US20080011764A1 - Method and System for High-Speed Tablet Counting and Dispensing - Google Patents
Method and System for High-Speed Tablet Counting and Dispensing Download PDFInfo
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- US20080011764A1 US20080011764A1 US11/860,596 US86059607A US2008011764A1 US 20080011764 A1 US20080011764 A1 US 20080011764A1 US 86059607 A US86059607 A US 86059607A US 2008011764 A1 US2008011764 A1 US 2008011764A1
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- tablets
- chambers
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- chamber
- counting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B57/00—Automatic control, checking, warning, or safety devices
- B65B57/20—Applications of counting devices for controlling the feed of articles
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61J—CONTAINERS SPECIALLY ADAPTED FOR MEDICAL OR PHARMACEUTICAL PURPOSES; DEVICES OR METHODS SPECIALLY ADAPTED FOR BRINGING PHARMACEUTICAL PRODUCTS INTO PARTICULAR PHYSICAL OR ADMINISTERING FORMS; DEVICES FOR ADMINISTERING FOOD OR MEDICINES ORALLY; BABY COMFORTERS; DEVICES FOR RECEIVING SPITTLE
- A61J7/00—Devices for administering medicines orally, e.g. spoons; Pill counting devices; Arrangements for time indication or reminder for taking medicine
- A61J7/02—Pill counting devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
- B65B5/10—Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles
- B65B5/101—Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles by gravity
- B65B5/103—Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles by gravity for packaging pills or tablets
Definitions
- This invention relates broadly to medicament tablet counting and dispensing apparatus. More particularly, this invention relates to tablet feeding and counting apparatus which are adapted to dispense any selected number of tablets, up to a maximum number, without a delay associated with counting the tablets.
- tablettes In retail, hospital, and mail order medication dispensing, a large number of different prescriptions of single dose medications, such as tablets, must be filled. (Hereinafter, reference to “tablets” should be understood for purposes herein as being generic to tablets, capsules, caplets and any other solid dose medication).
- an automatic tablet counter With an automatic tablet counter, the pharmacist obtains a bulk container of a prescription medication from a shelf and then pours from the container a quantity of tablets into a hopper of the counting apparatus. The pharmacist then sets the counting apparatus to the number of tablets to be counted, e.g., ninety. Assuming at least the required number of tablets for the prescription has been poured into the hopper, the pharmacist waits while the counting apparatus counts the required number of tablets and dispenses the tablets into a patient prescription bottle. The excess tablets are discharged back into the bulk container, which is then replaced on the shelf. It has been found that the time taken to discharge the excess tablets can be equal to or greater than the time required to count the prescription.
- Each prescription medication must be obtained from a bulk storage container located in stock, which must be opened prior to use and closed after use.
- cassette counters for retail, hospital, and mail order pharmacies.
- Each cassette is designed for a specific size and shape capsule, tablet, or caplet.
- the cassettes are pre-filled by the pharmacist with bulk quantities of the appropriate prescription drugs, and are used to store bulk quantities rather than using the container supplied by the manufacturer.
- the prescription medication is then dispensed directly from the cassette.
- the use of cassettes eliminates the time needed to open the manufacturer's original container, the time needed to return excess tablets to the container, and the time needed to close the container.
- a system and method for storing and dispensing discrete objects such as ‘tablets’ (stated above to be generic for tablets, capsules, caplets and any other solid dose medication), is provided and adapted to dispense a number of tablets, up to a maximum number, without a delay associated with counting the tablets.
- tablettes stated above to be generic for tablets, capsules, caplets and any other solid dose medication
- the system and methodology include first counting and storing a preset number of tablets in respective dedicated chambers (storage locations), the combination of the numbers of tablets within the chambers being useful for dispensing commonly prescribed numbers of tablets.
- n chambers are provided, with 2 0 , 2 1 , 2 2 , . . . , 2 n ⁇ 1 tablets provided respectively in the individual chambers.
- the system optionally can be hardwired to select the tablets from the required chambers without any combinatorial computation process; i.e., for any number of tablets selected for dispensing, there always exists a particular readily determinable combination of chambers which can be emptied to comprise the selected number of tablets exactly.
- the chambers can be selected by a simple computational process; i.e., first identifying the chamber having the largest number of tablets less than the selected number for dispensing, then identifying the chamber having the next largest number of tablets, provided that the addition of such number of tablets to the previously identified chamber does not exceed the selected number for dispensing, then identifying the chamber having the next largest number of tablets, provided that the addition of such number of tablets to the previously identified chambers does not exceed the selected number for dispensing, etc., until the desired number of tablets has been identified.
- the exit gates are released, preferably in succession, to dispense the tablets.
- a direct feed channel is provided in addition to the chambers.
- the direct feed channel feeds individually counted tablets into an exit chute in combination with the tablets dispensed from the chambers.
- the direct feed channel is primarily provided for counting up to 2 i+2 -1 tablets, where i preferably equals one, e.g., seven tablets.
- the chambers may store a non-exponentially incremented number of tablets, and that the direct feed channel may be used to supply up to another number of tablets.
- each chamber i may include subchambers which are each filled with the appropriate number of tablets for the chamber. Then, when activated, a subchamber of the chamber is emptied. The remaining filled subchambers are then ready for subsequent dispensing while the emptied subchamber is being refilled. As such, the user is not required to wait before attempting to dispense another prescription for the tablets. Moreover, during a single dispensing operation more than one subchamber of a chamber may be emptied, particularly when large numbers of tablets are to be dispensed.
- an overflow chamber may be provided for extra tablets which are inadvertently fed into the refill system after the required count to fill one or more of the chambers has been met. A count is kept of the tablets in the overflow chamber, and the overflow chamber is emptied during the subsequent dispensing or when the number therein is suitable in combination with one or more other chambers to meet an input number of tablets for dispensing.
- the system may include a plurality of cells, each including a plurality of chambers for a different solid dose medication.
- the solid dose medication may then be selected along with the number of tablets required to be dispensed.
- FIG. 1 is a schematic view of an object counting and dispensing system according to the invention including a cell provided with chambers having tablets;
- FIGS. 2, 3 and 4 are schematic views of the object counting and dispensing system of FIG. 1 , showing a sequence for release and closure of exit gates;
- FIGS. 5, 6 and 7 are schematic views of the object counting and dispensing system of FIG. 1 , showing a sequence for opening and closure of refill gates;
- FIG. 8 is a schematic section of a side elevation view of a first embodiment of a multi-cell object counting and dispensing system
- FIG. 9 is a schematic section view through line 9 - 9 in FIG. 8 ;
- FIG. 10 is a schematic view of a second embodiment of a multi-cell object counting and dispensing system
- FIG. 11 is a perspective view of another embodiment of an object counting and dispensing system according to the invention.
- FIG. 12 is a schematic view of the system of FIG. 11 .
- a tablet dispensing system 10 which includes a hopper 12 which stores a bulk quantity of tablets, a feeder 14 which feeds tablets from the hopper 12 to a cell 16 , which is described in more detail below, a counter 18 which counts the tablets fed by the feeder to the cell 16 , and a controller 34 which operates the cell 16 and permits a user to enter or select the number of tablets to be dispensed.
- the hopper 12 , feeder 14 and counter 18 may be of any type known in the art suitable for counting small discrete objects, such as tablets.
- the hopper 12 and feeder 14 may be a vibratory bowl feeder, a mechanical feeder, or a cassette system such as described in co-pending U.S. Ser. No. 09/871,531, filed May 31, 2001, which is hereby incorporated by reference herein in its entirety, each of which may have an integrated unit which functions as both a hopper and a feeder.
- the counter 18 is preferably an optical system which uses an optical sensor array, such as that disclosed in co-owned U.S. Pat. No. 5,768,327, which is hereby incorporated by reference herein in its entirety.
- the optical sensor array of U.S. Pat. No. 5,768,327 includes an orthogonal arrangement of two discrete optical sensors which together sense objects in three dimensions. This sensor arrangement is adapted to sense multiple objects simultaneously falling past the sensors.
- the cell 16 includes a plurality of vertically-stacked inclined chambers (storage locations) 20 positioned below the counter 18 . Seven chambers sequentially numbered one through seven are shown in the embodiment of FIG. 1 .
- the chambers 20 each have a fill gate 22 and an exit gate 24 . When the fill gate 22 of any chamber is open, that chamber is in communication with a feed chute 26 and thereby adapted to receive tablets 28 fed from the feeder 14 and counted by the counter 18 . With the respective exit gates 24 closed, each chamber 20 stores a predetermined, and preferably different, number of tablets.
- the exit gate 24 of any chamber when the exit gate 24 of any chamber is in an open position, the tablets stored within the chamber 20 are released into an exit chute 30 , and from the exit chute 30 the tablets are dispensed into a container 32 .
- the fill gates and exit gates are preferably electromechanically controlled, e.g., with solenoids powered by the controller 34 , to effect movement of the gates between open and closed positions.
- the combination of the numbers of tablets within the plurality of chambers 20 is capable of comprising any number of tablets which is desired for dispensing.
- n chambers are provided, with 2 0 , 2 2 , 2 2 . . . 2 2n ⁇ 1 tablets provided respectively in the individual chambers 20 .
- the chambers are provided with tablets as follows: chamber one includes one tablet (2 0 ); chamber two includes two tablets (2 1 ); chamber three includes four tablets (2 2 ); chamber four includes eight tablets (2 3 ) chamber five includes sixteen tablets (2 4 ); chamber six includes thirty-two tablets (2 5 ) and chamber seven includes sixty-four tablets (2 6 ).
- the controller 34 which causes the exit gates 24 of chambers two, four and five to be opened.
- the gates may be opened simultaneously. However, in the embodiment of the invention as shown, where the gates swing open, the gates are preferably opened in succession and at time intervals, e.g., 0.25 seconds between each opening, starting with the gate of the lowermost chamber. The time interval prevents jamming by the tablets.
- the exit gates are opened, the tablets in the respective chambers (two, eight, and sixteen tablets, respectively) are released into the exit chute 30 .
- the sixteen tablets from chamber five fall directly into the container, while the tablets from chambers four and two are retained the open exit gates of chambers five and four respectively.
- the exit gates 24 are then closed from the bottom up, preferably again in succession and at a short time interval, to release the retained tablets into the chute 30 for dispensing. That is, when the exit gate 24 of chamber five is closed, the tablets from chamber four which were resting on that gate are released to fall through the exit chute 30 and into the container. Likewise, when the exit gate 24 of chamber four is closed, the two tablets retainer from chamber two fall into the container 32 . Referring to FIG. 4 , the exit gate 24 of chamber two, previously holding the two tablets is then closed.
- the system optionally can be hardwired at the controller 34 to open the exit gates from the required chambers without any combinatorial computation process; i.e., for any number of tablets selected for dispensing, there always exists a particular readily determinable combination of chambers which can be emptied to comprise the selected number of tablets exactly, up to the maximum number of tablets stored in the cell 16 .
- the chambers can be selected by a simple computational process performed by the controller 34 , for example, by first identifying the chamber having the largest number of tablets less than the selected number for dispensing, then identifying the chamber having the next largest number of tablets, provided that the addition of such number of tablets to the previously identified chamber does not exceed the selected number for dispensing, then identifying the chamber having the next largest number of tablets, provided that the addition of such number of tablets to the previously identified chambers does not exceed the selected number for dispensing, etc., until the desired number of tablets has been identified.
- the exit gates are opened and closed, preferably in succession as described above, to dispense the tablets.
- the tablet dispensing system requires no tablet counting time because the chambers of the cell are preloaded. The only time required is for the gates to open to release and empty the tablets from the identified chambers. While time is required to refill the emptied chambers, the refill occurs after dispensing and presumably while the system operator is completing the prescription requirement (e.g., labeling, data entry, packaging, etc.) or identifying and/or preparing the subsequent prescription information; i.e., refill occurs during system operator downtime.
- the prescription requirement e.g., labeling, data entry, packaging, etc.
- the fill gates 22 of the emptied chambers are opened, and the tablets 28 are fed by the feeder 14 from the hopper 12 to the counter 18 (which is preferably an optical counter such as disclosed in co-owned U.S. Pat. No. 5,768,327).
- the counter 18 which is preferably an optical counter such as disclosed in co-owned U.S. Pat. No. 5,768,327.
- a tablet dispensing system 110 may include a plurality of radially arranged cells 116 each including a plurality of chambers 120 for a different solid dose medication.
- Each of the cells 116 is preferably provided with its own hopper 112 , feeder 114 and counter 118 .
- the solid dose medication may be selected from a controller (not shown) along with the number of tablets required to be dispensed.
- a common exit chute 130 can be used for dispensing into a bottle or container.
- Each cell 216 includes its own hopper 212 and preferably a feeder 214 .
- a common counter 218 may be movable between the hoppers 212 , feeders 214 , and the cells 216 .
- the feeder 214 may be integrated with the counter 218 and also movable relative to the hoppers 212 and cells 216 . From the above multi-cell system embodiments, is understood that various other configurations of a multi-cell system may be implemented.
- While the preferred system includes cells with n chambers provided with 2 0 ,2 1 , 2 2 , . . . , 2 n ⁇ 1 tablets in the respective chambers, it will be appreciated that chambers having another arrangement of tablet quantities may be used, provided that such arrangement permits the desired number of tablets to be dispensed. It is appreciated that not every number of tablet need be able to be dispensed, just those quantities which are generally prescribed. Prescribed quantities are generally in multiples of 7 or 10.
- the system 310 generally includes many of the features described above, including a hopper 12 , a feeder 14 , and a counter 18 .
- the system 310 also includes a cell 316 preferably having n primary chambers 320 for storing tablets, where n is preferably greater than or equal to four.
- a first chamber 320 a preferably includes eight tablets
- a second chamber 320 b preferably includes sixteen tablets
- a third chamber 320 c preferably includes 32 tablets
- a fourth chamber 320 d preferably includes 64 tablets.
- the cell 316 preferably also includes a fifth chamber 320 e , the purpose of which is described further below.
- the chambers are adapted to dispense a large range of numbers of tablets, between 8 and 120 tablets, and even up to 240 using multiple chambers and double dispensing, as discussed below.
- a direct feed channel 340 is provided in addition to the cell 316 .
- the direct feed channel 340 provides automatic feed-through of individually counted tablets in a manner which bypasses the chambers 320 of the cell 316 .
- the direct feed channel 340 is primarily provided for counting up to the number of tablets stored in the cell chamber having the fewest number of tablets. For example, if the first chamber 320 a stores eight tablets, the direct feed channel 340 is provided for automatically feeding up to seven tablets into the chute 330 .
- each chamber 320 preferably includes a plurality of subchambers, such as 342 , 344 , 346 .
- Each of the subchambers 342 , 344 , 346 can be provided with the respective number of tablets for that chamber 320 . That is, if a chamber 320 is designated to dispense eight tablets at a time, then each of the subchambers 342 , 344 , 346 is preferably provided with eight tablets, though it is appreciated that at any given time one or two of the subchambers may be emptied of tablets and awaiting refill.
- the chambers 320 are generally circular, with the subchambers 342 , 344 , 346 defined by sectors formed by radially extending walls 348 located 120° apart about a central hub 350 .
- the chambers 320 are preferably mounted for individual mechanical rotational movement by a motorized actuation mechanism 352 .
- the circumference of each circular chamber 320 includes a rim 353 which preferably extends within a stationary guide 355 at the bottom of the gateway 360 , described below, to facilitate rotational alignment of the chambers 320 .
- the chambers 320 also include an outer wall 354 provided with openings 356 into each of the subchambers.
- An enclosure 358 is provided partially about the cell 316 to retain tablets in the subchambers 342 , 344 , 346 and limit release of the tablets within the subchambers.
- the enclosure 358 has upper and lower apertures (not shown) which permit tablets to be received into the chamber and dispensed therefrom.
- a subchamber is oriented in a first direction, e.g., vertically upwards, the subchamber is positioned to receive tablets fed through its opening via the gateway 360 .
- the subchamber is oriented vertically downwards, the subchamber is oriented to empty its tablet contents via its opening 356 into the chute 330 .
- the subchamber and enclosure 358 merely store tablet contents.
- the necessary chambers to comprise the largest number of tablets smaller than the input number are actuated, e.g., by rotation, to empty their contents.
- all chambers are rotated and only the necessary chambers (or subchambers) are emptied, e.g., by providing actuatable gates at the openings to the subchambers.
- tablets are automatically fed into the direct feed channel 340 to complete the required number of tablets. For example, if an input is received to dispense ninety tablets, the fourth, second and first chambers are rotated to empty eighty-eight (64+16+8) tablets, and the direct feed provides an additional two tablets, for a total of ninety tablets.
- the cell may be actuated to release two subchambers, each with sixty-four tablets from the fourth chamber 320 d , one subchamber with thirty-two tablets from the third chamber 320 c , and one subchamber of sixteen tablets from the second chamber 320 b .
- Four tablets automatically fed from the feeder 14 to the direct feed channel 340 complete the request.
- the gateway 360 is a series of channels including the above described direct feed channel 340 and chamber channels 364 , 366 , 368 , 370 which direct tablets from a funnel 372 below the feeder 14 and into the chambers 320 a - e .
- Appropriate channels 340 , 364 , 366 , 368 , 370 are selected by operation of a plurality of actuatable gates 374 .
- the gates 374 are movable between opened and closed positions to, at any given time, define a single path for a tablet from the funnel 372 to one of the channels 340 , 364 , 366 , 368 , 370 . This permits subchambers to be refilled with the designated number of tablets after a dispensing operation, as well as the output of individual tablets through the direct feed channel 340 .
- the gates 374 move to a default position whereby such an extra tablet is provided to the fifth chamber 320 e .
- the fifth chamber 320 e operates as a temporary repository for such tablets. Generally, no more than one extra tablet would be counted per chamber. As such, with four chambers, up to four tablets may be provided to the fifth chamber upon each refill of the chambers.
- a count is kept of the tablets in the fifth chamber 320 e , and the tablets in the fifth chamber are preferably dispensed along with the tablets in other appropriate chambers (i) when the number in the fifth chamber 320 e is suitable in combination with one or more other chambers 320 a , 320 b , 320 c , 320 d to meet an input number of tablets for dispensing, or (ii) during every dispensing in combination with one or more other chambers and an appropriate number of tablets provided through the direct feed channel 340 .
- the first chamber may be set to have more than eight tablets and that direct feed may be used for more than seven tablets.
- the chambers have been described as having exponentially incremented numbers of tablets, it is appreciated that it may be desirable to fill the chambers with numbers of tablets which are multiples of seven and/or ten, in view of the fact that most prescriptions comprise a number of tablets in a multiple of seven or ten.
- the number of tablets designated for a particular chamber can be altered via software or hardware.
- controller may comprise two or more discrete systems; e.g., a system which permits user input, a system which controls gate operation, a system which controls the feeder, and a system which communicates with the object counter to turn off the feeder once the required number of tablets have been counted.
- system is described with respect to dispensing tablets, it will be appreciated that the system and method apply to the dispensing of other relatively small discrete objects.
- aspects of one embodiment may be combined with aspects of another embodiment. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
Abstract
Description
- This application is a continuation-in-part of U.S. Ser. No. 10/430,117, filed on May 6, 2003, which is a continuation-in-part of 09/975,608, filed Oct. 11, 2001, each incorporated by reference herein in its entirety.
- 1. Field of the Invention
- This invention relates broadly to medicament tablet counting and dispensing apparatus. More particularly, this invention relates to tablet feeding and counting apparatus which are adapted to dispense any selected number of tablets, up to a maximum number, without a delay associated with counting the tablets.
- 2. State of the Art
- In retail, hospital, and mail order medication dispensing, a large number of different prescriptions of single dose medications, such as tablets, must be filled. (Hereinafter, reference to “tablets” should be understood for purposes herein as being generic to tablets, capsules, caplets and any other solid dose medication).
- Larger quantity prescriptions are often filled with the aid of a counting apparatus intended to more rapidly count different quantities of different tablets successively. For example, a prescription for ninety tablets of 10 mg Claritin® may need to be filled after a prescription for sixty tablets of 400 mg Motrin®.
- With an automatic tablet counter, the pharmacist obtains a bulk container of a prescription medication from a shelf and then pours from the container a quantity of tablets into a hopper of the counting apparatus. The pharmacist then sets the counting apparatus to the number of tablets to be counted, e.g., ninety. Assuming at least the required number of tablets for the prescription has been poured into the hopper, the pharmacist waits while the counting apparatus counts the required number of tablets and dispenses the tablets into a patient prescription bottle. The excess tablets are discharged back into the bulk container, which is then replaced on the shelf. It has been found that the time taken to discharge the excess tablets can be equal to or greater than the time required to count the prescription.
- Each prescription medication must be obtained from a bulk storage container located in stock, which must be opened prior to use and closed after use. In order to minimize the time taken to dispense a prescription, counter manufacturers have provided “cassette counters” for retail, hospital, and mail order pharmacies. Each cassette is designed for a specific size and shape capsule, tablet, or caplet. The cassettes are pre-filled by the pharmacist with bulk quantities of the appropriate prescription drugs, and are used to store bulk quantities rather than using the container supplied by the manufacturer. The prescription medication is then dispensed directly from the cassette. The use of cassettes eliminates the time needed to open the manufacturer's original container, the time needed to return excess tablets to the container, and the time needed to close the container.
- However, there are situations, particularly in bulk mail order pharmacies and high volume hospital dispensing, where greater dispensing speed is desired than is currently provided by automatic dispensing systems, particularly for the most frequently dispensed medications.
- It is therefore an object of the invention to provide a system for dispensing a selected quantity of tablets extremely rapidly, irrespective of the type of tablet and the quantity of tablets dispensed.
- It is another object of the invention to provide a system for dispensing tablets which functions with all tablets regardless of size, shape, and weight.
- It is an additional object of the invention to provide a system for dispensing tablets which is not prone to clogging.
- It is a further object of the invention to provide a system for dispensing tablets which is efficient.
- In accord with these objects, which will be discussed in detail below, a system and method for storing and dispensing discrete objects, such as ‘tablets’ (stated above to be generic for tablets, capsules, caplets and any other solid dose medication), is provided and adapted to dispense a number of tablets, up to a maximum number, without a delay associated with counting the tablets.
- The system and methodology include first counting and storing a preset number of tablets in respective dedicated chambers (storage locations), the combination of the numbers of tablets within the chambers being useful for dispensing commonly prescribed numbers of tablets.
- According to one embodiment of the invention, n chambers are provided, with 20, 21, 22, . . . , 2n−1 tablets provided respectively in the individual chambers. Using such a system, any number of tablets, up to the additive combination of all the chambers (e.g., where n=7, the additive combination is 127), can be dispensed from the chambers by selectively emptying the chambers which together add up to the selected number for dispensing.
- Because the number of tablets in each of the chambers is always the same, the system optionally can be hardwired to select the tablets from the required chambers without any combinatorial computation process; i.e., for any number of tablets selected for dispensing, there always exists a particular readily determinable combination of chambers which can be emptied to comprise the selected number of tablets exactly. Alternatively, the chambers can be selected by a simple computational process; i.e., first identifying the chamber having the largest number of tablets less than the selected number for dispensing, then identifying the chamber having the next largest number of tablets, provided that the addition of such number of tablets to the previously identified chamber does not exceed the selected number for dispensing, then identifying the chamber having the next largest number of tablets, provided that the addition of such number of tablets to the previously identified chambers does not exceed the selected number for dispensing, etc., until the desired number of tablets has been identified. As each chamber is identified, or after all have been identified, the exit gates are released, preferably in succession, to dispense the tablets.
- According to another embodiment of the invention, there are n chambers, where n preferably equals at least four, and the number of tablets in a particular chamber i is preferably 2i+2, where i=1 . . . n. In accord with this embodiment, a direct feed channel is provided in addition to the chambers. The direct feed channel feeds individually counted tablets into an exit chute in combination with the tablets dispensed from the chambers. The direct feed channel is primarily provided for counting up to 2i+2-1 tablets, where i preferably equals one, e.g., seven tablets. As such, the direct feed channel in combination with the chambers permits dispensing of any number of tablets up to
e.g. where n=4, up to 127 tablets. However, it is certainly appreciated that the chambers may store a non-exponentially incremented number of tablets, and that the direct feed channel may be used to supply up to another number of tablets. - After the selected chambers are emptied tablets are fed from a feeder which stores bulk quantities of the tablet, counted, and directed into the emptied chambers to refill the chambers with the preset number of tables. The direction of the tablets into the emptied chambers for filling is preferably controlled by refill gates which open to receive or direct the required number of tablets and close once appropriately refilled. It is appreciated that only those chambers which are emptied after dispensing need to be refilled and, as such, only the number of tablets in those storage locations need to be counted.
- According to another aspect of the invention, each chamber i may include subchambers which are each filled with the appropriate number of tablets for the chamber. Then, when activated, a subchamber of the chamber is emptied. The remaining filled subchambers are then ready for subsequent dispensing while the emptied subchamber is being refilled. As such, the user is not required to wait before attempting to dispense another prescription for the tablets. Moreover, during a single dispensing operation more than one subchamber of a chamber may be emptied, particularly when large numbers of tablets are to be dispensed.
- In addition, an overflow chamber may be provided for extra tablets which are inadvertently fed into the refill system after the required count to fill one or more of the chambers has been met. A count is kept of the tablets in the overflow chamber, and the overflow chamber is emptied during the subsequent dispensing or when the number therein is suitable in combination with one or more other chambers to meet an input number of tablets for dispensing.
- The system may include a plurality of cells, each including a plurality of chambers for a different solid dose medication. The solid dose medication may then be selected along with the number of tablets required to be dispensed.
- Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
-
FIG. 1 is a schematic view of an object counting and dispensing system according to the invention including a cell provided with chambers having tablets; -
FIGS. 2, 3 and 4 are schematic views of the object counting and dispensing system ofFIG. 1 , showing a sequence for release and closure of exit gates; -
FIGS. 5, 6 and 7 are schematic views of the object counting and dispensing system ofFIG. 1 , showing a sequence for opening and closure of refill gates; -
FIG. 8 is a schematic section of a side elevation view of a first embodiment of a multi-cell object counting and dispensing system; -
FIG. 9 is a schematic section view through line 9-9 inFIG. 8 ; -
FIG. 10 is a schematic view of a second embodiment of a multi-cell object counting and dispensing system; -
FIG. 11 is a perspective view of another embodiment of an object counting and dispensing system according to the invention; and -
FIG. 12 is a schematic view of the system ofFIG. 11 . - Turning now to
FIG. 1 , atablet dispensing system 10 is shown which includes ahopper 12 which stores a bulk quantity of tablets, afeeder 14 which feeds tablets from thehopper 12 to acell 16, which is described in more detail below, acounter 18 which counts the tablets fed by the feeder to thecell 16, and acontroller 34 which operates thecell 16 and permits a user to enter or select the number of tablets to be dispensed. - The
hopper 12,feeder 14 and counter 18 may be of any type known in the art suitable for counting small discrete objects, such as tablets. For example, thehopper 12 andfeeder 14 may be a vibratory bowl feeder, a mechanical feeder, or a cassette system such as described in co-pending U.S. Ser. No. 09/871,531, filed May 31, 2001, which is hereby incorporated by reference herein in its entirety, each of which may have an integrated unit which functions as both a hopper and a feeder. Thecounter 18 is preferably an optical system which uses an optical sensor array, such as that disclosed in co-owned U.S. Pat. No. 5,768,327, which is hereby incorporated by reference herein in its entirety. The optical sensor array of U.S. Pat. No. 5,768,327 includes an orthogonal arrangement of two discrete optical sensors which together sense objects in three dimensions. This sensor arrangement is adapted to sense multiple objects simultaneously falling past the sensors. - The
cell 16 includes a plurality of vertically-stacked inclined chambers (storage locations) 20 positioned below thecounter 18. Seven chambers sequentially numbered one through seven are shown in the embodiment ofFIG. 1 . Thechambers 20 each have afill gate 22 and anexit gate 24. When thefill gate 22 of any chamber is open, that chamber is in communication with afeed chute 26 and thereby adapted to receivetablets 28 fed from thefeeder 14 and counted by thecounter 18. With therespective exit gates 24 closed, eachchamber 20 stores a predetermined, and preferably different, number of tablets. As discussed in more detail below, when theexit gate 24 of any chamber is in an open position, the tablets stored within thechamber 20 are released into anexit chute 30, and from theexit chute 30 the tablets are dispensed into acontainer 32. The fill gates and exit gates are preferably electromechanically controlled, e.g., with solenoids powered by thecontroller 34, to effect movement of the gates between open and closed positions. - The combination of the numbers of tablets within the plurality of
chambers 20 is capable of comprising any number of tablets which is desired for dispensing. According to a preferred system, n chambers are provided, with 20, 22, 22 . . . 22n−1 tablets provided respectively in theindividual chambers 20. Using such a system, any number of tablets, up to the additive combination of all the chambers (e.g., where n=8, the additive combination is 255), can be dispensed by selectively emptying the chambers which together add up to the selected number for dispensing. - As shown in
FIG. 1 , in an embodiment of the invention, sevenchambers 20 are provided; i.e., n=7. The chambers are provided with tablets as follows: chamber one includes one tablet (20); chamber two includes two tablets (21); chamber three includes four tablets (22); chamber four includes eight tablets (23) chamber five includes sixteen tablets (24); chamber six includes thirty-two tablets (25) and chamber seven includes sixty-four tablets (26). - Referring to
FIG. 2 , if it is desired to dispense, e.g., twenty-six tablets, twenty-six tablets are selected at thecontroller 34 which causes theexit gates 24 of chambers two, four and five to be opened. The gates may be opened simultaneously. However, in the embodiment of the invention as shown, where the gates swing open, the gates are preferably opened in succession and at time intervals, e.g., 0.25 seconds between each opening, starting with the gate of the lowermost chamber. The time interval prevents jamming by the tablets. As the exit gates are opened, the tablets in the respective chambers (two, eight, and sixteen tablets, respectively) are released into theexit chute 30. The sixteen tablets from chamber five fall directly into the container, while the tablets from chambers four and two are retained the open exit gates of chambers five and four respectively. Referring toFIG. 3 , theexit gates 24 are then closed from the bottom up, preferably again in succession and at a short time interval, to release the retained tablets into thechute 30 for dispensing. That is, when theexit gate 24 of chamber five is closed, the tablets from chamber four which were resting on that gate are released to fall through theexit chute 30 and into the container. Likewise, when theexit gate 24 of chamber four is closed, the two tablets retainer from chamber two fall into thecontainer 32. Referring toFIG. 4 , theexit gate 24 of chamber two, previously holding the two tablets is then closed. - As is discussed hereinafter, because the number of tablets in each of the
particular chambers 20 is kept constant (due to refilling), the system optionally can be hardwired at thecontroller 34 to open the exit gates from the required chambers without any combinatorial computation process; i.e., for any number of tablets selected for dispensing, there always exists a particular readily determinable combination of chambers which can be emptied to comprise the selected number of tablets exactly, up to the maximum number of tablets stored in thecell 16. - Alternatively, the chambers can be selected by a simple computational process performed by the
controller 34, for example, by first identifying the chamber having the largest number of tablets less than the selected number for dispensing, then identifying the chamber having the next largest number of tablets, provided that the addition of such number of tablets to the previously identified chamber does not exceed the selected number for dispensing, then identifying the chamber having the next largest number of tablets, provided that the addition of such number of tablets to the previously identified chambers does not exceed the selected number for dispensing, etc., until the desired number of tablets has been identified. As each chamber is identified, or after all have been identified, the exit gates are opened and closed, preferably in succession as described above, to dispense the tablets. - The tablet dispensing system requires no tablet counting time because the chambers of the cell are preloaded. The only time required is for the gates to open to release and empty the tablets from the identified chambers. While time is required to refill the emptied chambers, the refill occurs after dispensing and presumably while the system operator is completing the prescription requirement (e.g., labeling, data entry, packaging, etc.) or identifying and/or preparing the subsequent prescription information; i.e., refill occurs during system operator downtime.
- After the identified chambers have been emptied, such chambers need to be refilled for subsequent dispensing operations. Referring now to
FIG. 5 , thefill gates 22 of the emptied chambers (chambers two, four, and five in the example) are opened, and thetablets 28 are fed by thefeeder 14 from thehopper 12 to the counter 18 (which is preferably an optical counter such as disclosed in co-owned U.S. Pat. No. 5,768,327). Once the counter counts the required number of tablets for the uppermost emptied chamber (chamber two), and after a short predetermined delay to permit the tablets to fall through thefill chute 26 to the respective chamber, the fill gate of that chamber is closed, as shown inFIG. 6 . Still referring toFIG. 6 , then the tablets required for the next chamber (i.e., chamber four) are counted, enter the fill chute and fall through the open fill gate to the chamber. Referring toFIG. 7 , once chamber four is refilled, itsrespective fill gate 22 is closed, and chamber five is refilled in a like manner. It is appreciated that only those chambers which are emptied after dispensing need to be refilled and, as such, only the number of tablets in those chambers need to be counted. It is also appreciated that the dispensing system is initialized by counting and directing the required number of tablets to each of the respective chambers. - Referring to
FIGS. 8 and 9 , atablet dispensing system 110 may include a plurality of radially arrangedcells 116 each including a plurality ofchambers 120 for a different solid dose medication. Each of thecells 116 is preferably provided with itsown hopper 112,feeder 114 andcounter 118. The solid dose medication may be selected from a controller (not shown) along with the number of tablets required to be dispensed. Acommon exit chute 130 can be used for dispensing into a bottle or container. - Turning now to
FIG. 10 , another embodiment of a multi-celltablet dispensing system 210 is shown. Eachcell 216 includes itsown hopper 212 and preferably afeeder 214. Acommon counter 218 may be movable between thehoppers 212,feeders 214, and thecells 216. Alternatively, thefeeder 214 may be integrated with thecounter 218 and also movable relative to thehoppers 212 andcells 216. From the above multi-cell system embodiments, is understood that various other configurations of a multi-cell system may be implemented. - While the preferred system includes cells with n chambers provided with 20,21, 22, . . . , 2n−1 tablets in the respective chambers, it will be appreciated that chambers having another arrangement of tablet quantities may be used, provided that such arrangement permits the desired number of tablets to be dispensed. It is appreciated that not every number of tablet need be able to be dispensed, just those quantities which are generally prescribed. Prescribed quantities are generally in multiples of 7 or 10.
- Turning now to
FIGS. 11 and 12 , another embodiment of adispensing system 310 for tablets is shown. Thesystem 310 generally includes many of the features described above, including ahopper 12, afeeder 14, and acounter 18. Thesystem 310 also includes acell 316 preferably having n primary chambers 320 for storing tablets, where n is preferably greater than or equal to four. The number of tablets in a particular chamber i is preferably 2i+2, where i=1 . . . n. Thus, for exactly four chambers 320, according to a presently preferred embodiment, afirst chamber 320 a preferably includes eight tablets, asecond chamber 320 b preferably includes sixteen tablets, athird chamber 320 c preferably includes 32 tablets, and afourth chamber 320 d preferably includes 64 tablets. Thecell 316 preferably also includes afifth chamber 320 e, the purpose of which is described further below. With four primary chambers, the chambers are adapted to dispense a large range of numbers of tablets, between 8 and 120 tablets, and even up to 240 using multiple chambers and double dispensing, as discussed below. - A
direct feed channel 340 is provided in addition to thecell 316. Thedirect feed channel 340 provides automatic feed-through of individually counted tablets in a manner which bypasses the chambers 320 of thecell 316. Thedirect feed channel 340 is primarily provided for counting up to the number of tablets stored in the cell chamber having the fewest number of tablets. For example, if thefirst chamber 320 a stores eight tablets, thedirect feed channel 340 is provided for automatically feeding up to seven tablets into thechute 330. As such, for n=4, the chambers 320 in combination with thedirect feed channel 340 permit dispensing of any number of tablets up to
(i.e., 127 tablets), without requiring three additional chambers for 1 (20), 2 (21) and 4 (22) tablets, as in the prior embodiments. Moreover, there is no need to direct feed more tablets than already pre-counted and stored in a chamber. - According to a preferred aspect of the invention, each chamber 320 preferably includes a plurality of subchambers, such as 342, 344, 346. Each of the
subchambers subchambers subchambers walls 348 located 120° apart about acentral hub 350. The chambers 320 are preferably mounted for individual mechanical rotational movement by amotorized actuation mechanism 352. The circumference of each circular chamber 320 includes arim 353 which preferably extends within astationary guide 355 at the bottom of thegateway 360, described below, to facilitate rotational alignment of the chambers 320. The chambers 320 also include anouter wall 354 provided withopenings 356 into each of the subchambers. Anenclosure 358, shown in broken lines, is provided partially about thecell 316 to retain tablets in thesubchambers enclosure 358 has upper and lower apertures (not shown) which permit tablets to be received into the chamber and dispensed therefrom. When a subchamber is oriented in a first direction, e.g., vertically upwards, the subchamber is positioned to receive tablets fed through its opening via thegateway 360. When a subchamber is oriented vertically downwards, the subchamber is oriented to empty its tablet contents via itsopening 356 into thechute 330. When a subchamber is oriented such that its opening is not adjacent thegateway 360 orchute 330, the subchamber andenclosure 358 merely store tablet contents. - Upon receiving an input for dispensing a certain number of tablets, the necessary chambers to comprise the largest number of tablets smaller than the input number are actuated, e.g., by rotation, to empty their contents. Alternatively, all chambers are rotated and only the necessary chambers (or subchambers) are emptied, e.g., by providing actuatable gates at the openings to the subchambers. If necessary, tablets are automatically fed into the
direct feed channel 340 to complete the required number of tablets. For example, if an input is received to dispense ninety tablets, the fourth, second and first chambers are rotated to empty eighty-eight (64+16+8) tablets, and the direct feed provides an additional two tablets, for a total of ninety tablets. - According to another aspect of the invention, it may be desirable to be able to dispense a relatively large number of tablets by emptying more than one subchamber of a chamber. For example, if the number of tablets input for dispensing is one hundred-eighty, and the cell includes four primary chambers, each with three subchambers, of which two such subchambers of each chamber are preferably filled at any one time, the cell may be actuated to release two subchambers, each with sixty-four tablets from the
fourth chamber 320 d, one subchamber with thirty-two tablets from thethird chamber 320 c, and one subchamber of sixteen tablets from thesecond chamber 320 b. Four tablets automatically fed from thefeeder 14 to thedirect feed channel 340 complete the request. - After a dispensing operation, tablets are fed from the feeder through the
gateway 360 to the appropriate chambers for subchamber refilling. Thegateway 360 is a series of channels including the above describeddirect feed channel 340 andchamber channels funnel 372 below thefeeder 14 and into the chambers 320 a-e.Appropriate channels actuatable gates 374. Thegates 374 are movable between opened and closed positions to, at any given time, define a single path for a tablet from thefunnel 372 to one of thechannels direct feed channel 340. - After a subchamber is filled with the appropriate number of tablets, it is possible that an additional tablet will have already been fed by the
feeder 14 to thecounter 18, but not yet counted. As such, after filling a chamber, thegates 374 move to a default position whereby such an extra tablet is provided to thefifth chamber 320 e. Thefifth chamber 320 e operates as a temporary repository for such tablets. Generally, no more than one extra tablet would be counted per chamber. As such, with four chambers, up to four tablets may be provided to the fifth chamber upon each refill of the chambers. A count is kept of the tablets in thefifth chamber 320 e, and the tablets in the fifth chamber are preferably dispensed along with the tablets in other appropriate chambers (i) when the number in thefifth chamber 320 e is suitable in combination with one or moreother chambers direct feed channel 340. Emptying thefifth chamber 320 e whenever tablets are stored therein, regardless of how many tablets are in the fifth chamber, prevents inadvertent storage of a relatively large number of tablets which may be difficult to dispense in combination with the other chambers 320 a-d. - In the above embodiment, it is recognized that the first chamber may be set to have more than eight tablets and that direct feed may be used for more than seven tablets. Moreover, while the chambers have been described as having exponentially incremented numbers of tablets, it is appreciated that it may be desirable to fill the chambers with numbers of tablets which are multiples of seven and/or ten, in view of the fact that most prescriptions comprise a number of tablets in a multiple of seven or ten. Moreover, the number of tablets designated for a particular chamber can be altered via software or hardware.
- There have been described and illustrated herein several embodiments of a tablet dispensing system and a method of dispensing tablets. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while the gates may be operated with a solenoid, it is appreciated that other means for moving the gates may be used. Also, while swinging gates have been disclosed, it will be appreciated that other types of gates can be utilized. In fact, if vertical space is provided between chambers, vertically moving gates may be utilized, and, in some embodiments, when vertically moving gates are utilized, all gates may be opened simultaneously, and all tablets may be dispensed immediately. In addition, while a particular number of chambers have been shown in each cell, it will be understood that other numbers of chambers may be used. Moreover, in one embodiment, while the number of tablets in each of the chambers is shown to increase with the successively lower located chambers, it is understood that the number of tablets designated for the chambers can be otherwise organized, e.g., a decreasing number of tablets as the chambers are located lower, or with another order to the number of tablets in relation to the location of the chambers. In addition, while a controller is shown, it is appreciated that the controller may comprise two or more discrete systems; e.g., a system which permits user input, a system which controls gate operation, a system which controls the feeder, and a system which communicates with the object counter to turn off the feeder once the required number of tablets have been counted. Also, while the system is described with respect to dispensing tablets, it will be appreciated that the system and method apply to the dispensing of other relatively small discrete objects. Furthermore, aspects of one embodiment may be combined with aspects of another embodiment. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
Claims (6)
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US8855811B1 (en) | 2008-07-30 | 2014-10-07 | Kirby Lester, Llc | Pharmacy workflow management system including plural counters |
US9977871B2 (en) | 2014-01-14 | 2018-05-22 | Capsa Solutions Llc | Cassette control including presence sensing and verification |
US10583941B2 (en) | 2017-10-13 | 2020-03-10 | Rxsafe Llc | Universal feed mechanism for automatic packager |
US11305898B2 (en) | 2017-10-13 | 2022-04-19 | Rxsafe Llc | Universal feed mechanism for automatic packager |
US20210101703A1 (en) * | 2018-06-21 | 2021-04-08 | Phc Holdings Corporation | Drug supplying device and drug packaging device |
US11873125B2 (en) * | 2018-06-21 | 2024-01-16 | Phc Holdings Corporation | Drug supplying device and drug packaging device |
WO2020202032A1 (en) * | 2019-04-05 | 2020-10-08 | Blue Sky Ventures (Ontario) Inc. | Gating system for accumulating items and related filling machine and methods |
US11155378B2 (en) * | 2019-04-05 | 2021-10-26 | Blue Sky Ventures? (Ontario) Inc. | Gating system for accumulating items and related filling machine and methods |
Also Published As
Publication number | Publication date |
---|---|
US7073544B2 (en) | 2006-07-11 |
US7383862B2 (en) | 2008-06-10 |
US20050189365A1 (en) | 2005-09-01 |
US6684914B2 (en) | 2004-02-03 |
US20030070725A1 (en) | 2003-04-17 |
US6899144B1 (en) | 2005-05-31 |
US20060237093A1 (en) | 2006-10-26 |
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