Prescription filling apparatus implementing a pick and place method

• US 20040034447A1
• Filed: 04/25/2003
• Published: 02/19/2004
• Est. Priority Date: 08/09/2002
• Status: Active Grant

• Current Assignee: McKesson Automation Incorporated (Omnicell Inc)
• Original Assignee: McKesson Automation Incorporated (Omnicell Inc)
• Inventors: Vollm, James
• Granted Patent: US 7,228,198 B2
• Time in Patent Office: Days
• US Class Current: 700/235
• CPC Class Codes: A61J 7/02 Pill counting devices
• CPC Class Codes: B65B 5/103 for packaging pills or tablets
• CPC Class Codes: B65B 57/20 Applications of counting devices for controlling the feed of articles other applications B65B65/08
• CPC Class Codes: G07F 11/44 in which magazines the articles are stored in bulk
• CPC Class Codes: G07F 11/54 about vertical axes
• CPC Class Codes: G07F 11/58 the articles being supported on or by endless belts or like conveyors
• CPC Class Codes: G07F 11/62 in which the articles are stored in compartments in fixed receptacles
• CPC Class Codes: G07F 17/0092 for assembling and dispensing of pharmaceutical articles medical dispensers for private use, A61J7/00

Abstract

An apparatus for filling vials comprises a shelving unit defining an array of storage locations. The shelving unit may be an array in an XY plane or one or more carousels. A plurality of storage containers are provided, each removably carried by one of the storage locations. A counting and dispensing unit, a source of vials, a label printer and application unit or units, and an output device are also provided. The output device may take a variety of forms such as an output chute, which is preferably used when a capping unit is provided, an output conveyor, a plurality of output lanes, and an output carousel, which may be a dedicated carousel or a portion of the carousel providing the plurality of storage locations. A computer controlled engagement device provides motion in a Z direction. The engagement device may be comprised of a first stage for engaging the storage containers and a second stage for engaging the vials. A computer controlled system carries the engagement device and moves the engagement device in XY directions among the plurality of storage locations, counting and dispensing unit, source of vials, label printer and application unit, and output device. Methods of operating and refilling the vial filling apparatus are also disclosed.

Claims

1. An automated apparatus for filling vials, comprising:

a shelving unit defining an array of storage locations;

a plurality of storage containers, each removably carried by one of said storage locations;

a counter and dispenser;

a source of vials;

a label printer and applier;

an output device;

a computer controlled engagement device, said engagement device providing motion in a Z direction;

a computer controlled system for carrying said engagement device and for moving said engagement device in X-Y directions among said plurality of storage locations, said counter and dispenser, said source of vials, said label printer and applier, and said output device.

2. The apparatus of claim 1 wherein said shelving unit includes one of a linear array in the XY directions and an array carried by a carousel.

3. The apparatus of claim 2 wherein said output device is formed by a portion of said carousel.

4. The apparatus of claim 1 wherein said engagement device includes a passive engagement mechanism and wherein said storage containers include a passive engagement mechanism.

5. The apparatus of claim 4 wherein said passive engagement mechanism of said storage containers includes one of a channel or a member for insertion into said channel, and wherein the passive engagement mechanism of said engagement device includes the other of one of a channel or a member for insertion into said channel.

6. The apparatus of claim 5 wherein said passive engagement mechanism of said engagement device is rotatable about an axis in the Y direction.

7. The apparatus of claim 4 wherein said engagement device additionally comprises a gripper for engaging a vial.

8. The apparatus of claim 1 wherein said engagement device comprises a screw extending in the Z direction to enable said engagement device to move in the Z direction.

9. The apparatus of claim 1 wherein said output device includes one of an output chute, an output conveyor, a plurality of output lanes and an output carousel.

10. The apparatus of claim 1 wherein said system for carrying said engagement device comprises one of a screw drive, pulley drive, chain drive and gear drive for moving said engagement device in the XY directions.

11. The apparatus of claim 1 wherein said system for carrying said engagement device is one of electrically, pneumatically, and hydraulically driven.

12. The apparatus of claim 1 wherein said shelving unit comprises a carousel, said apparatus additionally comprising a computer for controlling said carousel, said engagement device and said system for carrying said engagement device.

13. An automated apparatus for filling vials, comprising:

a shelving unit defining an array of storage locations;

a plurality of storage containers, each removably carried by one of said storage locations;

a counter and dispenser;

a source of vials;

a label printer and applier;

an output device;

a computer controlled engagement device, said engagement device having a first stage for engaging said storage containers and a second stage for engaging said vials;

a computer controlled system for carrying said engagement device and for moving said engagement device among said plurality of storage locations, said counter and dispenser, said source of vials, said label printer and applier, and said output device.

14. The apparatus of claim 13 wherein said shelving unit includes one of a linear array in the XY directions and an array carried by a carousel.

15. The apparatus of claim 14 wherein said output device is formed by a portion of said carousel.

16. The apparatus of claim 13 wherein said first stage of said engagement device includes a passive engagement mechanism and wherein said storage containers include a passive engagement mechanism.

17. The apparatus of claim 16 wherein said passive engagement mechanism of said storage containers includes one of a channel or a member for insertion into said channel, and wherein the passive engagement mechanism of said engagement device includes the other of one of a channel or a member for insertion into said channel.

18. The apparatus of claim 17 wherein said passive engagement mechanism of said engagement device is rotatable about an axis in the Y direction.

19. The apparatus of claim 16 wherein said second stage of said engagement device includes a gripper for engaging a vial.

20. The apparatus of claim 13 wherein said engagement device comprises a screw extending in the Z direction to enable said engagement device to move in the Z direction.

21. The apparatus of claim 13 wherein said output device includes one of an output chute, an output conveyor, a plurality of output lanes and an output carousel.

22. The apparatus of claim 13 wherein said system for carrying said engagement device comprises one of a screw drive, pulley drive, chain drive and gear drive for moving said engagement device.

23. The apparatus of claim 13 wherein said system for carrying said engagement device is one of electrically, pneumatically, and hydraulically driven.

24. The apparatus of claim 13 wherein said shelving unit comprises a carousel, said apparatus additionally comprising a computer for controlling said carousel, said engagement device and said system for carrying said engagement device.

25. The apparatus of claim 13 wherein said shelving unit comprises a left carousel, said apparatus additionally comprising a second shelving unit comprising a right carousel, and wherein said first stage of said engagement device rotates between approximately +90°

and −

60°

as measured from an insertion position for said counter and dispenser to retrieve cassettes from said left carousel and said right carousel, respectively.

26. A method comprising:

moving cassettes using one stage of an engagement device; and

moving vials using another stage of the engagement device.

27. The method of claim 26 wherein said moving using one stage of an engagement device and said moving using another stage of the engagement device includes moving said stages of said engagement device together in the XY directions and independently in a Z direction.

28. The method of claim 26 wherein said moving of cassettes includes passively gripping the cassette and wherein said moving a vial includes actively gripping the vial.

29. The method of claim 26 wherein moving cassettes includes moving cassettes between an array of storage locations and a counter and dispenser;

and wherein said moving vials includes moving a vial among a vial store, a label printer and applier, a counter and dispenser, and an output location.

30. The method of claim 29 wherein said moving a vial to an output location includes selecting an output location based on an order grouping criterion.

31. A method, comprising:

rotating a carousel into a pick position;

removing a cassette from the carousel and placing the cassette in a counting and dispensing unit;

moving a vial from a vial source to a counting and dispensing unit;

dispensing from the cassette into the vial;

moving the vial to an output position; and

returning the cassette to the carousel.

32. The method of claim 31 additionally comprising selecting a carousel to rotate into a pick position.

33. The method of claim 31 additionally comprising removing a cassette from the carousel and placing the cassette in an input/output area.

34. The method of claim 33 wherein a cassette in placed in the input/output area for one of refilling, servicing and swapping stock.

35. The method of claim 31 wherein said moving the vial to an output position includes selecting an output position based on an order grouping criterion.

36. The method of claim 31 additionally comprising capping the vial after said dispensing.

37. The method of claim 31 additionally comprising printing and applying a label to the vial.

38. An automated apparatus of the type having a housing containing a plurality of devices for implementing a method of filling vials, the improvement comprising:

an input/output housing having a back barrier facing the interior of the apparatus and a front barrier facing the exterior of the apparatus, an input/output area being defined between said front and said rear barriers; and

an interlock preventing both said back barrier and said front barrier from being unlocked at the same time.

39. An automated apparatus for filling vials, comprising:

a housing defining an interior and an exterior of said apparatus;

a shelving unit defining an array of storage locations and located in said interior;

a plurality of storage containers, each removably carried by one of said storage locations;

a counter and dispenser located in said interior;

a source of vials having at least a dispensing end accessible to said interior;

an output device having an input end accessible to said interior and an output end accessible to said exterior;

a computer controlled robot capable of movement in the X, Y and Z directions for movement among said plurality of storage locations, said counter and dispenser, said source of vials, and said output device;

an input/output housing having a rear barrier between said input/output housing and said interior and a front barrier between said input/output housing and said exterior, an input/output area being defined between said front and said rear barriers; and

an interlock for preventing both said rear barrier and said front barrier from being unlocked at the same time.

40. A method, comprising:

moving a selected vial from a vial source to a counter;

moving a selected cassette carrying medication to be dispensed to the counter;

dispensing a number of medication units from said selected cassette to said vial;

removing said vial from said counter;

removing said selected cassette from said counter; and

in parallel with the foregoing;

opening a rear barrier to an input/output area;

moving another cassette to said input/output area;

closing and locking said rear barrier; and

unlocking a front barrier.

41. A method, comprising:

moving a selected vial from a vial source to a counter;

moving a selected cassette carrying medication to be dispensed to the counter;

dispensing a number of medication units from said selected cassette to said vial;

removing said vial from said counter;

removing said selected cassette from said counter; and

in parallel with the foregoing;

opening a front barrier to an input/output area;

moving another cassette to said input/output area;

closing and locking said front barrier; and

unlocking a rear barrier.

42. A method of filling a vial using a pick and place method implemented by computer controlled equipment located in the interior of a housing, the improvement comprising:

one of adding cassettes to and removing cassettes from the interior of the housing while vials are being filled in a manner that prevents objects from being inserted directly into the interior of the housing from the exterior of the housing.