Positive count rotary slat packaging apparatus and related methods

• US 20010045081A1
• Filed: 06/07/2001
• Published: 11/29/2001
• Est. Priority Date: 05/20/1998
• Status: Active Grant

• Current Assignee: Aylacqco, LLC
• Original Assignee: Aylward Enterprises, Inc.
• Inventors: Aylward, John T.
• Granted Patent: US 6,401,429 B2
• Time in Patent Office: Days
• US Class Current: 53/244
• CPC Class Codes: B65B 35/08 using pocketed conveyors
• CPC Class Codes: B65B 5/103 for packaging pills or tablets
• CPC Class Codes: B65B 57/14 and operating to control, or stop, the feed of articles or material to be packaged
• CPC Class Codes: B65B 57/20 Applications of counting devices for controlling the feed of articles other applications B65B65/08
• CPC Class Codes: Y10S 53/90 Capsules

Abstract

An automated positive count rotary slat packaging apparatus and related methods include independently rotatable rotary slats. In one embodiment, the apparatus also includes a positive count mechanism disposed in the pill delivery path adjacent the containers and a controller which is capable of generating an alarm or determining when a bottle is filled incorrectly. Accordingly, underfilled containers can be independently filled by further rotating only the respective rotary slat. A drive device for each rotary slat is also provided having frustoconical drive wheels connected to the ends of counterrotating drive shafts. The drive wheels, which are driven by a motor, engage corresponding frustoconical drive surfaces of the rotary slats to thereby rotate the slats.

Claims

1. An automated packaging apparatus for depositing a predetermined number of pills into a series of containers, comprising:

a reservoir configured to hold a plurality of pills and defining at least one opening adjacent a lower portion thereof;

a plurality of rotary slats each having a peripheral edge portion rotatable into the opening in said reservoir, said peripheral edge portions of said rotary slats each defining a plurality of pill receptacles configured to capture an individual pill at a first position in said reservoir and release the pill at a second position outside of said reservoir;

a conveyor configured to move a plurality of open containers along a predetermined path of travel and position each container adjacent a respective rotary slat to define a delivery path extending between the second position of said rotary slat and the container such that the pills are released from said slat and fall along said delivery path into the corresponding container;

a plurality of drive motors each in driving engagement with one of said rotary slats for rotating the respective slat; and

a controller connected to each of said drive motors for independently controlling said drive motors such that said slats can be rotated for different durations.

2. A packaging apparatus according to

claim 1

wherein each drive motor is capable of rotating at different speeds such that said rotary slats can be driven at different speeds.

3. A packaging apparatus according to

claim 1

further comprising a plurality of stationary spacers, at least one of said spacers being disposed intermediate each adjoining pair of rotary slats.

4. A packaging apparatus according to

claim 3

wherein each of said spacers further defines a pressurized air passageway therein in fluid communication with each of said pill receptacles of an adjacent rotary slat when the respective receptacles are in said second position, said passageways directing a blast of air into the receptacle to assist in the release of the pill engaged therein at said second position.

8. A packaging apparatus according to

claim 1

further comprising:

a second conveyor configured to move a second plurality of open containers along a predetermined path of travel and position each of the containers of the second plurality adjacent a container of the first plurality and the respective rotary slat; and

a chute positioned below each of the rotary slats, said chute being selectively movable to define a first delivery path extending between the second position of the rotary slat and a container of the first plurality and to further define a second delivery path extending between the second position of the rotary slat and a container of the second plurality, such that the pills are released from said rotary slat and can be selectively guided to fall along one of said delivery paths and into the corresponding container.

5. A packaging apparatus according to

claim 5

further comprising a common support shaft on which said rotary slats are mounted.

6. A packaging apparatus according to

claim 5

wherein said common support shaft is supported at only one end such that the rotary slats can be removed over the opposite free end of the shaft.

7. A packaging apparatus according to

claim 5

wherein each of said rotary slats is interchangeable in position in said apparatus with another of said rotary slats.

9. An automated packaging apparatus for depositing a predetermined number of pills into a series of containers, comprising:

a reservoir configured to hold a plurality of pills and defining at least one opening adjacent a lower portion thereof;

a plurality of rotary slats each having a peripheral edge portion rotatable into the opening in said reservoir, said peripheral edge portions of said rotary slats each defining a plurality of pill receptacles configured to capture an individual pill at a first position in said reservoir and release the pill at a second position outside of said reservoir;

a conveyor configured to move a plurality of open containers along a predetermined path of travel and position each container adjacent a respective rotary slat to define a delivery path extending between the second position of said rotary slat and the container such that the pills are released-from the slat and fall along said delivery path into the corresponding container; and

a counting device disposed along each of said delivery paths for counting pills delivered along the path such that the number of pills passing into each container can be positively determined.

10. A packaging apparatus according to

claim 9

wherein each of said counting devices is disposed adjacent to the respective open container and includes a light source which generates a continuous beam of light across the delivery path and an opposing light receiver which senses when the light is interrupted by each pill passing into the container.

11. A packaging apparatus according to

claim 10

wherein said light source generates a planar beam which extends across the delivery path and is substantially parallel to an adjacent opening of each container.

12. A packaging apparatus according to

claim 9

further comprising an alarm in association with said counting devices which generates an alert when any one of the containers does not contain a predetermined number of pills after a predetermined amount of time.

13. A packaging apparatus according to

claim 9

further comprising a second counting device disposed along each of said delivery paths for counting pills delivered along the path.

14. An automated packaging apparatus for depositing a predetermined number of pills into a series of containers, comprising:

a reservoir configured to hold a plurality of pills and defining at least one opening adjacent a lower portion thereof;

a plurality of rotary slats each having a peripheral edge portion rotatable into the opening in said reservoir, said peripheral edge portions of said rotary slats each defining a plurality of pill receptacles configured to capture an individual pill at a first position in said reservoir and release the pill at a second position outside of said reservoir;

a conveyor configured to move a plurality of open containers along a predetermined path of travel and position each container adjacent a respective rotary slat to define a delivery path extending between the second position of said rotary slat and the container such that the pills are released from the slat and fall along said delivery path into the corresponding container;

a plurality of drive motors each in driving engagement with one of said rotary slats for rotating the respective slat;

a controller connected to each of said drive motors for independently controlling said drive motors; and

a counting device disposed along each of said delivery paths for counting pills delivered along the path, said counting devices being in operative communication with said controller such that the number of pills passing into each container can be positively determined and the rotary slats can be individually rotated until a predetermined number of pills has been deposited into the respective container.

15. A packaging apparatus according to

claim 14

wherein said drive motors are capable of rotating at different speeds including a first speed at which the rotary slats are driven for a first predetermined number of pills and a second speed slower than said first at which said rotary slats are driven for a second predetermined number of pills, thereby preventing overfilling of the container.

16. An automated packaging apparatus for depositing a predetermined number of pills into a container, comprising:

a reservoir configured to hold a plurality of pills and defining at least one opening adjacent a lower portion thereof;

a rotary slat having a peripheral edge portion rotatable into the opening in said reservoir, said peripheral edge portion defining a plurality of pill receptacles configured to capture an individual pill at a first position in said reservoir and release the pill at a second position outside of said reservoir after rotation of the slat, said rotary slat defining a frustoconical drive surface;

a rotatable drive motor;

a drive shaft connected to the drive motor; and

a drive wheel connected to the drive shaft and having a frustoconical drive surface in engagement with the drive surface of the rotary slat such that rotation of the drive motor causes a corresponding rotation of the rotary slat.

17. A packaging apparatus according to

claim 16

wherein the rotary slat further comprises a second frustoconical drive surface opposite the first frustoconical drive surface, and wherein said apparatus further comprises:

a second drive shaft connected to the drive motor for rotation in a direction opposite the direction of rotation of the first drive shaft; and

a second drive wheel connected to the second drive shaft and having a frustoconical drive surface in engagement with the second drive surface of the rotary slat.

18. A packaging apparatus according to

claim 17

further comprising an actuator for disengaging the first and second drive wheels from the rotary slat.

19. A packaging apparatus according to

claim 17

further comprising a device for pressing the drive surfaces of the drive wheels against the drive surfaces of the rotary slat with substantially uniform force.

20. A packaging apparatus according to

claim 17

further comprising a pneumatic cylinder for moving the drive motor, drive shafts and drive wheels towards the rotary slat.

21. A packaging apparatus according to

claim 16

further comprising a plurality of rotary slats arranged side-by-side and corresponding pluralities of drive motors and drive shafts for driving each of the rotary slats.

22. A packaging apparatus according to

claim 21

wherein the drive shafts for alternating ones of the rotary slats are aligned in a common plane and the drive shafts for the other alternating ones of the rotary slats are aligned in a common plane separate from the first plane.

23. A packaging apparatus according to

claim 21

wherein each drive motor is capable of rotating at different speeds such that said rotary slats can be driven at different speeds.

24. A packaging apparatus according to

claim 21

further comprising a common support shaft on which said rotary slats are mounted.

25. A packaging apparatus according to

claim 24

wherein each of the rotary slats is mounted on the common support shaft by a plain bearing.

26. A drive device for driving a rotary slat of a pill packaging apparatus, said drive device comprising:

a rotatable drive motor;

a first drive shaft connected to the drive motor;

a second drive shaft connected to the drive motor for rotation in a direction opposite the direction of the first drive shaft; and

first and second drive wheels connected to the respective drive shafts and being spaced apart by a predetermined distance for engagement on opposing sides of the rotary slat, such that rotation of the drive motor causes a corresponding rotation of the rotary i15 slat.

27. A drive device as defined in

claim 26

wherein each of the drive wheels has a frustoconical drive surface for engaging and driving the rotary slat.

28. A drive device as defined in

claim 26

further comprising an actuator for disengaging the first and second drive wheels from the rotary slat.

29. A drive device as defined in

claim 28

where in said actuator further comprises a pneumatic cylinder for moving the drive motor, drive shafts and drive wheels towards and away from the rotary slat.

30. A drive device according to

claim 26

wherein the drive motor is capable of rotating at different speeds such that the rotary slat can be driven at different speeds.

31. An automated method of depositing a predetermined number of pills into a series of containers comprising the steps of:

capturing a plurality of pills in individual pill receptacles formed on a plurality of rotary slats;

rotating the rotary slats to a position where the pills are released from the receptacles thereby allowing the pills to fall from the receptacles into the containers and define a delivery path; and

counting each pill which falls along the delivery path of a rotary slat to positively determine to the number of pills deposited into the respective container.

32. A method of depositing pills as defined in

claim 31

wherein said rotating step further comprises rotating each of the rotary slats independently with a separate drive motor.

33. A method of depositing pills as defined in

claim 31

comprising the further step of comparing the number of pills deposited in each container with the number of pills deposited in at least one of the other containers.

34. A method of depositing pills as defined in

claim 31

further comprising the steps of conveying a series of empty containers adjacent to a respective slat and beginning the rotation of each slat at the same time and at the same speed.

35. A method of depositing pills as defined in

claim 31

further comprising the step of-stopping the rotation of the slats for which the respective containers have received a predetermined number of pills while continuing the rotation of any slats for which the respective container has not received the predetermined number of pills.

36. A method of depositing pills as defined in

claim 31

further comprising the step of directing pressurized air into the individual receptacles during said rotating step to assist in the release of the pill engaged in the receptacle.

37. A method of depositing pills as defined in

claim 31

wherein said counting step further comprises directing a continuous beam of light across the delivery path and sensing interruptions in the beam of light caused by individual pills falling along the delivery path.

38. A method of depositing pills as defined in

claim 32

wherein said rotating step further comprises rotating the drive motors at a first speed until a first predetermined number of pills has been deposited in the containers and then rotating the drive motors at a slower second speed until a second predetermined number of pills has been deposited to prevent overfilling of the container.