Vacuum based pill singulator and counter based thereon

• US 20050224510A1
• Filed: 10/25/2004
• Published: 10/13/2005
• Est. Priority Date: 03/15/2004
• Status: Active Grant

• Current Assignee: Parata Systems, LLC (Becton, Dickinson & Co)
• Original Assignee: Parata Systems, LLC (Becton, Dickinson & Co)
• Inventors: Volker, John, Rhodes, Raymond, Hahn, Adam, Remis, Steven J.
• Granted Patent: US 8,020,724 B2
• Time in Patent Office: Days
• US Class Current: 221/69
• CPC Class Codes: B65B 35/06 Separating single articles from loose masses of articles
• 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 11/1657 the picking arrangements using suction
• CPC Class Codes: G07F 17/0092 for assembling and dispensing of pharmaceutical articles medical dispensers for private use, A61J7/00
• CPC Class Codes: G16H 20/13 delivered from dispensers

Abstract

A singulating disc, carried by a housing, has a plurality of openings around its periphery. The disc rotates vertically through a pickup chamber of a hopper carried by the housing. A vacuum is pulled through the openings by a pump which is connected to the disc. Items are placed in the hopper and, via gravity, fall to the bottom of the hopper where they contact the periphery of the rotating disc. The vacuum at the openings attaches an item and holds it while the disc rotates. At the top of the disc'"'"'s rotation, a diverter directs the item into a path depending on the results of a fragment detection and/or counting mechanism. Items that are allowed to pass by the diverter are scraped off the disc into another path by a scraper. Negative pressure is used to singulate and count a multitude of sizes and shapes of items with no calibration. Retractable paddles, a vacuum management system, and RFID tags may be incorporated. The paddles aid in the pickup and agitation of the items while the vacuum management system conserves the vacuum capacity necessary to pickup and singulate items. The RFID tags may contain information such as the number of items left in the hopper, a par level for that item, an expiration date, among others. Because of the rules governing abstracts, this abstract should not be used to construe the claims.

Claims

1. A singulating device, comprising:

a housing;

a hopper defining a pickup chamber, said hopper connected to said housing;

a rotatable singulating disc carried by said housing, said disc having a plurality of openings around the periphery thereof, a portion of said disc rotating through said pickup chamber;

a source of rotary motion coupled to said singulating disc;

a vacuum source coupled to said singulating disc;

an inspection and counting device; and

means responsive to said inspection and counting device for removing items from said singulating disc in a manner that directs the removed items into one of a dispense path, a reject path, and a return to pickup chamber path.

2. The singulating device of claim 1 wherein said means for removing includes a diverter responsive to said inspection and counting device and a scraper for removing items that pass by said diverter.

3. The singulating device of claim 2 wherein said diverter includes one of a mechanical diverter or a nozzle connectable to a source of pressurized gas.

4. The singulating device of claim 2 wherein said diverter includes a U-shaped member having a divert to the right position, a divert to the left position and a pass position.

5. The singulating device of claim 1 wherein said singulating disc is hollow and has a tapered periphery.

6. The singulating device of claim 1 wherein said singulating disc is hollow and has a rubber surface along said periphery.

7. The singulating device of claim 1 wherein said hopper is removable, said removable hopper having said pickup chamber and certain of said paths formed therein, said hopper being connectable to said housing.

8. The singulating device of claim 7 additionally comprising an RFID tag carried by said removable hopper, and a tag reader carried by said housing.

9. The singulating device of claim 8 wherein said RFID tag includes a tag into which information may be written.

10. The singulating device of claim 9 wherein said information includes at least one of a quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

11. A singulating device, comprising:

a housing;

a hopper defining a pickup chamber, said hopper connected to said housing;

a hollow, rotatable singulating disc carried by said housing, said disc having a plurality of openings around the periphery thereof, a portion of said disc rotating through said pickup chamber, said disc having a plurality of retractable paddles extendable from said periphery, each of said paddles having an actuating device extending through an opening in a face of said singulating disc;

a source of rotary motion coupled to said singulating disc;

a vacuum source coupled to said singulating disc;

at least one path;

means for removing items from the periphery of said singulating disc into said path; and

a cam positioned to interface with each of said actuating devices during a portion of rotation of said singulating disc such that each of said devices moves along said opening in a first direction to cause its respective paddle to extend beyond said periphery, and to move along said opening in a second direction opposite to said first direction to cause said paddle to retract as said device rides along said cam.

12. The singulating device of claim 11 wherein said cam is movable between a first position in which said cam interfaces with said actuating devices and a second position in which said cam does not interface with said actuating devices.

13. The singulating device of claim 11 additionally comprising an input splitter responsive to said source of rotary motion for providing motion in one direction for operating said singulating disc and for providing motion in another direction for positioning said cam.

14. The singulating device of claim 11 wherein said retractable paddles are each comprised of a plurality of retractable, parallel pins.

15. The singulating device of claim 14 wherein said pickup chamber has a plurality of parallel grooves formed therein for receiving said parallel pins when said pins are extended.

16. The singulating device of claim 11 wherein said hopper is removable, said removable hopper having said pickup chamber formed therein, said hopper being connectable to said housing.

17. The singulating device of claim 16 additionally comprising an RFID tag carried by said removable hopper, and a tag reader carried by said housing.

18. The singulating device of claim 17 wherein said RFID tag includes a tag into which information may be written.

19. The singulating device of claim 18 wherein said information includes at least one of a quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

20. The singulating device of claim 11 additionally comprising a plurality of pistons located within said singulating disc, each piston controlling the volume of air flowing through one of said plurality of openings around the periphery of the singulating disc.

21. A singulating device, comprising:

a housing;

a hopper defining a pickup chamber, said hopper connected to said housing;

a hollow, rotatable singulating disc carried by said housing, said disc having a plurality of openings around the periphery thereof, a portion of said disc rotating through said pickup chamber, said disc having a plurality of pistons, each piston positioned so as to control the volume of air flowing through one of said plurality of openings;

a source of rotary motion coupled to said singulating disc;

a vacuum source coupled to said singulating disc;

at least one path;

means for removing items from the periphery of said singulating disc into said path; and

a cam positioned to interface with each of said pistons such that air flow is at a maximum for each opening while said opening is located in said pickup chamber and is at a minimum when said opening is positioned at said means for removing.

22. The singulating device of claim 21 wherein said cam additionally interfaces with said pistons such that air flow is less than a maximum air flow during a portion of rotation of said disc from said pickup chamber to said means for removing.

23. The singulating device of claim 21 additionally comprising a plurality of retractable paddles extendable from said periphery of said disc, and a mechanism for extending and retracting said plurality of paddles as said disc rotates.

24. The singulating device of claim 21 wherein said hopper is removable, said removable hopper having said pickup chamber formed therein, said hopper being connectable to said housing.

25. The singulating device of claim 24 additionally comprising an RFID tag carried by said removable hopper, and a tag reader carried by said housing.

26. The singulating device of claim 25 wherein said RFID tag includes a tag into which information may be written.

27. The singulating device of claim 26 wherein said information includes at least one of a quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

28. A singulating device, comprising:

a housing;

a removable hopper having a pickup chamber accessed by a door, said hopper carried by said housing;

a rotatable singulating disc carried by said housing, said disc having a plurality of openings around the periphery thereof, a portion of said disc rotating through said pickup chamber when said hopper is attached to said housing;

a source of rotary motion coupled to said singulating disc;

a vacuum source coupled to said singulating disc;

at least one path; and

means for removing items from said singulating disc into said path;

said door on said hopper being configured to wipe any items from said singulating disc into said pickup chamber before removal of said hopper from said housing.

29. The singulating device of claim 28 wherein said singulating disc is hollow.

30. The singulating device of claim 29 additionally comprising a plurality of retractable paddles extendable from said periphery of said disc, and a mechanism for extending and retracting said plurality of paddles as said disc rotates.

31. The singulating device of claim 29 additionally comprising a plurality of pistons located within said singulating disc, each piston controlling the volume of air flowing through one of said plurality of openings around the periphery of the singulating disc.

32. The singulating device of claim 28 additionally comprising an RFID tag carried by said removable hopper, and a tag reader carried by said housing.

33. The singulating device of claim 32 wherein said RFID tag includes a tag into which information may be written.

34. The singulating device of claim 33 wherein said information includes at least one of a quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

35. A singulating device, comprising:

a housing;

a hopper defining a pickup chamber, said hopper connected to said housing;

a rotatable singulating disc carried by said housing, said disc having a plurality of openings around the periphery thereof, a portion of said disc rotating through said pickup chamber;

a source of rotary motion coupled to said singulating disc;

a vacuum source coupled to said singulating disc;

an inspection device; and

a U-shaped mechanical diverter positioned adjacent to said periphery of said singulating disc, said diverter having a first position for directing medicaments into a first path, a second position for directing medicaments into a second path, and a third position which allows medicaments to stay on said disc.

36. The singulating device of claim 35 additionally comprising a scraper, said first path being located to one side of said singulating disc, said second path being located to an opposite side of said singulating disc, and said third path being located to the rear of said diverter, and wherein said scraper removes medicaments from said singulating disc in a manner that directs the removed medicaments into a third path.

37. The singulating device of claim 36 additionally comprising two solenoids, said solenoids being responsive to said inspection device such that when one of said solenoids is energized said diverter is in said first position to direct a medicament into said first path, and when the other of said solenoids is energized said diverter is in said second position to direct a medicament into said second path, and when neither of said solenoids is energized said diverter is in said third position which enables a medicament to pass the diverter so as to be removed from said singulating disc by said scraper.

38. The singulating device of claim 37 additionally comprising a return spring for returning the diverter to said third position when neither of said solenoids is energized.

39. The singulating device of claim 35 wherein said hopper is removable, said removable hopper having said pickup chamber formed therein, said hopper being connectable to said housing.

40. The singulating device of claim 39 additionally comprising an RFID tag carried by said removable hopper, and a tag reader carried by said housing.

41. The singulating device of claim 40 wherein said RFID tag includes a tag into which information may be written.

42. The singulating device of claim 41 wherein said information includes at least one of a quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

43. A singulating device, comprising:

a housing;

a removable hopper defining a pickup chamber, said hopper being connectable to said housing;

an RFID tag carried by said hopper;

an RFID tag reader carried by said housing;

a rotatable singulating disc carried by said housing, said disc having a plurality of openings around the periphery thereof, a portion of said disc rotating through said pickup chamber;

a source of rotary motion coupled to said singulating disc;

a vacuum source coupled to said singulating disc;

a counting device; and

means responsive to said counting device for removing items from said singulating disc.

44. The singulating device of claim 43 wherein said singulating disc includes a hollow disc having a plurality of retractable paddles extendable from said periphery, each of said paddles having an actuating device extending through an opening in a face of said singulating disc, and a cam positioned to interface with each of said actuating devices during a portion of rotation of said singulating disc such that each of said devices moves along said opening in a first direction to cause its respective paddle to extend beyond said periphery, and to move along said opening in a second direction opposite to said first direction to cause said paddle to retract as said device rides along said cam.

45. The singulating device of claim 43 wherein said disc has a plurality of pistons, each piston positioned so as to control the flow of air flowing through one of said plurality of openings, and a cam positioned to interface with each of said pistons such that air flow is at a maximum for each opening while said opening is located in said pickup chamber and is at a minimum when said opening is positioned at said means for removing.

46. The singulating device of claim 43 wherein said means responsive to said counting device includes a U-shaped mechanical diverter positioned adjacent to said periphery of said singulating disc, said diverter having a first position for directing items into a first path, a second position for directing items into a second path, and a third position which allows items to remain on said disc.

47. The singulating device of claim 43 wherein said RFID tag includes a tag into which information may be written.

48. The singulating device of claim 47 wherein said information includes at least one of quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

49. A method of singulating items, comprising:

rotating a singulating disk through a pickup chamber while pulling a vacuum at a plurality of openings located around a periphery of the disc;

inspecting and counting the items captured by the singulating disc; and

removing the items captured by the singulating disc in a manner that the items are directed into one of a first, second or third path, based on said inspecting and counting.

50. The method of claim 49 wherein said inspecting includes determining if an item captured by the singulating disc may be dispensed and, if so, said removing step including directing said item into the first path and, if not, said removing step including directing said item into the second path.

51. The method of claim 50 additionally comprising directing the item into the third path in response to said counting.

52. The method of claim 49 additionally comprising controlling the volume of air flowing through each of said plurality of openings.

53. The method of claim 52 wherein said controlling includes maximizing the air flow when an opening is in the pickup chamber and minimizing the air flow for an opening during the removing of an item.

54. The method of claim 53 wherein said controlling includes regulating the air flow so that the air flow is less than maximum during a portion of rotation of the disc from the pickup chamber until the removing of the item.

55. The method of claim 49 additionally comprising controlling the extension and retraction of paddles from a periphery of the disc as the disc rotates.

56. The method of claim 55 additionally comprising ceasing the rotation of the disc and retracting all of said paddles.

57. The method of claim 56 including removing a hopper having the pickup chamber from a housing carrying the singulating disc.

58. The method of claim 49 additionally comprising attaching a hopper having the pickup chamber to a housing carrying the singulating disc and reading an RFID tag carried by the hopper.

59. The method of claim 58 wherein said reading includes reading at least one of a quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

60. A method of singulating items comprising:

rotating a portion of a hollow, singulating disc through a pickup chamber while pulling a vacuum at a plurality of openings located around a periphery of the disc, and as said disc is rotating;

extending paddles from the periphery of that portion of the singulating disc located in the pickup chamber;

retracting the extended paddles; and

removing items captured by the singulating disc.

61. The method of claim 60 including ceasing rotation of said disc and retracting all of said paddles.

62. The method of claim 61 including removing a hopper having the pickup chamber from a housing carrying the singulating disc.

63. The method of claim 60 including controlling the amount of air flowing through each of the plurality of openings as said disc is rotating.

64. The method of claim 63 wherein said controlling includes maximizing the air flow when an opening is in the pickup chamber and minimizing the air flow for an opening during the removing of an item.

65. The method of claim 64 wherein said controlling includes regulating the air flow so that it is less than maximum during a portion of rotation of the disc from the pickup chamber until the removing of the item.

66. The method of claim 60 additionally comprising attaching a hopper having the pickup chamber to a housing carrying the singulating disc and reading an RFID tag carried by the hopper.

67. The method of claim 66 wherein said reading includes reading at least one of a quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

68. A method of singulating items, comprising:

rotating a portion of a hollow, singulating disc through a pickup chamber while pulling a vacuum at a plurality of openings located around a periphery of the disc, and as said disc is rotating;

controlling the volume of air flowing through each of the plurality of openings; and

removing items captured by the singulating disc.

69. The method of claim 68 wherein said controlling includes maximizing the air flow when an opening is in the pickup chamber and minimizing the air flow for an opening during the removing of an item.

70. The method of claim 69 wherein said controlling includes regulating the air flow so that it is less than maximum during a portion of rotation of the disc from the pickup chamber until the removing of the item.

71. The method of claim 68 additionally comprising controlling the extension and retraction of paddles from a periphery of the disc as the disc rotates.

72. The method of claim 71 additionally comprising ceasing the rotation of the disc and retracting all of said paddles.

73. The method of claim 72 including removing a hopper having the pickup chamber from a housing carrying the singulating disc.

74. The method of claim 68 additionally comprising attaching a hopper having the pickup chamber to a housing carrying the singulating disc and reading an RFID tag carried by the hopper.

75. The method of claim 74 wherein said reading includes reading at least one of a quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

76. A method of singulating items, comprising:

attaching a hopper having a pickup chamber to a housing having a singulating disc;

rotating a portion of the singulating disc carried by said housing through the pickup chamber while pulling a vacuum at a plurality of openings located around the periphery of the disc;

removing items captured by the singulating disc;

ceasing rotation of said disc; and

detaching the hopper from said housing such that access doors on said hopper wipe any items from said disc into said pickup chamber as said hopper is detached and said access doors close.

77. The method of claim 76 additionally comprising controlling the volume of air flowing through each of the openings.

78. The method of claim 77 wherein said controlling includes maximizing the air flow when an opening is in the pickup chamber and minimizing the air flow for an opening during the removing of an item.

79. The method of claim 78 wherein said controlling includes regulating the air flow so that it is less than maximum during a portion of rotation of the disc from the pickup chamber until the removing of the item.

80. The method of claim 76 additionally comprising controlling the extension and retraction of paddles from a periphery of the disc as the disc rotates.

81. The method of claim 80 additionally comprising ceasing the rotation of the disc and retracting of said paddles.

82. The method of claim 76 additionally comprising reading an RFID tag carried by the hopper.

83. The method of claim 82 wherein said reading includes reading at least one of a quantity of items in the hopper, a par level for that item, an expiration date for the items and a location where the hopper is stored.

84. A method of singulating items, comprising:

rotating a singulating disc through a pickup chamber while pulling a vacuum at a plurality of openings located around the periphery of the disc;

counting the items captured by the singulating disc;

reading an RFID tag carried by a hopper in which the pickup chamber is formed; and

dispensing the items captured by the singulating disc in response to said counting.

85. The method of claim 84 additionally comprising inspecting an item captured by the singulating disc to determine if the item may be dispensed.

86. The method of claim 84 wherein said dispensing includes removing the items captured by the singulating disc.

87. The method of claim 86 additionally comprising controlling the volume of air flowing through each of said plurality of openings.

88. The method of claim 87 wherein said controlling includes maximizing the air flow when an opening is in the pickup chamber and minimizing the air flow for an opening during the removing of an item.

89. The method of claim 88 wherein said controlling includes regulating the air flow so that the air flow is less than maximum during a portion of rotation of the disc from the pickup chamber until the removing of the item.

90. The method of claim 84 additionally comprising controlling the extension and retraction of paddles from a periphery of the disc as the disc rotates.

91. The method of claim 90 additionally comprising ceasing the rotation of the disc and retracting all of said paddles.

92. The method of claim 91 including removing a hopper having the pickup chamber from a housing carrying the singulating disc.