Automated means for removing, parking and replacing a syringe tip cap from a syringe

• US 20040104243A1
• Filed: 04/30/2003
• Published: 06/03/2004
• Est. Priority Date: 12/03/2002
• Status: Active Grant

• Current Assignee: Baxter Corporation Englewood (Baxter International Inc.)
• Original Assignee: Forhealth Technologies Incorporated (Baxter International Inc.)
• Inventors: Osborne, Joel A., Tribble, Dennis, Aven, William C.
• Granted Patent: US 7,017,622 B2
• Time in Patent Office: Days
• US Class Current: 222/63
• CPC Class Codes: A61M 2005/3104 Caps for syringes without needle
• CPC Class Codes: B65B 3/003 Filling medical containers such as ampoules, vials, syringes or the like
• CPC Class Codes: B65B 7/161 Sealing filled ampoules
• CPC Class Codes: B65B 7/2821 applying plugs or threadless stoppers for bottles or jars B67B1/04

Abstract

In one exemplary embodiment, an automated syringe preparation mechanism for an automated medication preparation system is provided and the mechanism includes (1) a first automated gripping mechanism having a pair of adjustable gripper arms for removing a tip cap from a barrel of one syringe and placing the removed tip cap at a first location and (2) a second automated gripping mechanism having a pair of adjustable gripper arms for replacing the removed tip cap on the syringe barrel after the medication is injected therein.

Claims

1. An automated syringe preparation mechanism for an automated medication preparation system, the mechanism comprising:

a first automated gripping device for removing a tip cap from a barrel tip of one syringe and placing the removed tip cap at a first location; and

a second automated gripping device for replacing the removed tip cap on the syringe barrel after medication has been injected therein, wherein each of the first and second automated gripping devices is in communication with a programmable controller and each of the first and second gripping devices moves in at least two directions.

2. The automated syringe preparation mechanism of claim 1, wherein at least one of the first and second automated gripping devices has first and second gripping arms that are spaced apart from one another in an open position and are moved toward one another to a closed position so as to securely capture and hold the tip cap between the first and second gripping arms.

3. The automated syringe preparation mechanism of claim 2, wherein each of the first and second gripping arms has a platform with a shaped cut out formed at one edge thereof and the two shaped cut outs are aligned with one another so that when the gripping arms are in the closed position, the shaped cut outs define an opening that is sized to receive and hold the tip cap.

4. The automated syringe preparation mechanism of claim 1, wherein each of the first and second automated gripping devices is movable along an x axis and a y axis.

5. The automated syringe preparation mechanism of claim 1, wherein each of the first and second automated gripping devices has a first control mechanism for controlling opening and closing of gripper arms that grasp and retain the tip cap;

a second control mechanism for controlling up and down movement of the gripping device and a third control mechanism for controlling inward and outward movement of the gripping device.

6. The automated syringe preparation mechanism of claim 5, wherein each of the first, second and third control mechanisms is a pneumatic device that upon actuation causes movement of the device in at least one direction.

7. The automated syringe preparation mechanism of claim 1, further including:

a sensor device including at least one sensor that emits a light beam and a reflector for reflecting the light beam, the sensor device being mounted relative to gripper arms that grasp and retain the tip cap so that the light beam passes through a space between the gripper arms where the tip cap is received, the sensor device in communication with the programmable controller so that a control signal is delivered to the programmable controller when the tip cap is disposed within the space, thereby impinging the light beam.

8. The automated syringe preparation mechanism of claim 5, wherein each of the first and second automated gripper devices includes a vertical base with the gripper arms being disposed closer to an upper end of the vertical base, the second control mechanism operatively connected to the vertical base to cause controlled up and down movements thereof;

the third control mechanism operatively connected to the vertical base to cause controlled inward and outward movements thereof.

9. The automated syringe preparation mechanism of claim 8, wherein the second and third control mechanisms are one of pneumatic devices and mechanical motorized devices that each moves the vertical base between two positions.

10. The automated syringe preparation mechanism of claim 1, wherein the first and second automated gripping devices are the same.

11. The automated syringe preparation mechanism of claim 5, wherein the first automated gripping device is positionable between a starting position, a second position where the tip cap is grasped by the gripper arms for removal from the syringe and a third position where the tip cap is disposed over a feature for retainingly parking the tip cap.

12. The automated syringe preparation mechanism of claim 11, wherein the feature comprises a post that is formed as part of the support for receiving and holding the removed tip cap.

13. The automated syringe preparation mechanism of claim 1, wherein the automated medication preparation system includes an automated rotary device that is indexed to advance the syringe from one station to another station, the rotary device having a feature for holding the removed tip cap as the syringe is advanced from one station to the next.

14. The automated syringe preparation mechanism of claim 1, wherein each of the first and second automated gripper devices includes a vertical base that is movable at least in the x and y directions and a horizontal support member that extends outward from the vertical base and spaces the gripper arms away from the vertical base, the gripper arms being part of a pneumatic unit that is disposed at a distal end of the support member.

15. The automated syringe preparation mechanism of claim 14, further including:

a housing for each of the first and second automated gripper devices, the housing having an opening formed in an upper wall thereof to permit movement of the vertical base at least along an x axis and a y axis.

16. An automated device for removing a tip cap from an empty syringe, placing the tip cap at a remote location, and replacing the tip cap on a filled syringe, the device comprising:

a support frame that is movable along at least an x axis and a y axis;

a gripper mechanism including a pair of gripper arms that are positionable between an open position and a closed position in which the tip cap is securely held therebetween;

a programmable controller in communication with a plurality of drive actuators that controllably drive the gripper arms and the support frame to desired positions; and

a sensor for detecting whether the tip cap is disposed between the gripper arms.

17. The automated device according to claim 16, wherein the support frame comprises a vertical base that is operatively connected to a first control unit that moves the vertical base in a track along the y axis between inward and outward positions and a second control unit that moves the vertical base along the x axis between raised and lowered positions.

18. The automated device according to claim 16, wherein the gripper mechanism is operatively connected to a control unit that positions the gripper arms between the open and closed positions.

19. The automated device according to claim 16, wherein the sensor comprises a reflecting light emitting diode (LED).

20. The automated device according to claim 16, wherein the sensor is of a type that emits a light beam and a reflector is provided across from the sensor for reflecting the light beam, the sensor device being mounted relative to gripper arms that grasp and retain the tip cap so that the light beam passes through a space between the gripper arms where the tip cap is received, the sensor device in communication with the programmable controller so that a control signal is delivered to the programmable controller when the tip cap is disposed within the space, thereby impinging the light beam.

21. The automated device according to claim 16, wherein the plurality of drive actuators comprises a first pneumatic control device for controllably moving the support frame along the y axis and a second pneumatic control device for controllably moving the support frame along the x axis.

22. The automated device according to claim 16, wherein the plurality of drive actuators comprises a first motorized mechanical device mechanism for controllably moving the support frame along the y axis and a second motorized mechanical device mechanism for controllably moving the support frame along the x axis.

23. The automated device according to claim 16, wherein the support frame comprises a vertical base.

24. A method of removing, parking and replacing a tip cap from a syringe, the method comprising the steps of:

providing an automated device for removing the tip cap from an empty syringe, placing the tip cap at a remote location, and replacing the tip cap on a filled syringe, the device comprising a support frame that is movable along at least an x axis and a y axis;

a gripper mechanism including a pair of gripper arms that are positionable between an open position and a closed position in which the tip cap is securely held therebetween; and

a programmable controller in communication with a plurality of drive actuators that controllably drive the gripper arms and the support frame to desired positions;

moving the vertical base to a first position where the open gripper arms are disposed about the tip cap of the syringe;

closing the gripper arms to securely capture and retain the tip cap and moving the vertical base to a raised position to cause the removal of the tip cap as it is securely held between the gripper arms;

moving the vertical base so that the held tip cap is disposed above a remote feature for holding the removed tip cap and opening the gripper arms so that the tip cap falls onto the feature;

moving the vertical base and closing the gripper arms to as to securely retain the tip cap and lift it from the feature after the syringe has been filled; and

moving the vertical base to a position above the filled syringe and then lowering the held tip cap until the tip cap engages and is securely replaced on the processed syringe.

25. A method for just-in-time removal of a tip cap from a syringe barrel, filling the syringe with a prescribed dose of medication and replacing the tip cap on the syringe barrel, the method including the steps of:

securing the syringe barrel to a device of an automated preparation system;

gripping and removing the tip cap from the syringe barrel to open up an interior of the syringe barrel and placing the removed tip cap at a first location;

delivering the prescribed dose to the interior of the syringe barrel through the open syringe barrel;

gripping the removed tip cap at the first location and moving it to the syringe barrel containing the prescribed dose; and

replacing the tip cap on the syringe barrel.

26. The method of claim 25, wherein the step of securing the syringe barrel comprises the step of:

releasably holding the syringe barrel about a rotary device that advances the syringe from one station to a next station.

27. A method for automatically rejecting a syringe for filling if the syringe is advanced to a filling station without a tip cap securely attached to a barrel tip of the syringe, the method comprising the steps of:

determining with a sensor device whether the tip cap is securely attached to the syringe barrel and if the sensor detects that the tip cap is not securely attached to the syringe barrel, then the syringe is rejected and is not filled at the filling station; and

if the sensor device detects the presence of a tip cap, then the syringe is subjected to at least one device for automatically removing, parking the tip cap, filling the syringe and replacing the tip cap.

28. The method of claim 27, wherein the step of determining whether the tip cap is securely attached comprises the steps of:

emitting a light beam from the sensor device towards a reflector; and

detecting a reflected light beam in the event that the tip cap is not present on the syringe barrel, whereby a control signal is generated to indicate the absence of the tip cap, and in the event that the tip cap is present on the syringe barrel, the light beam does not impinge the reflector.