Automated drug preparation apparatus including automated drug reconstitution

• US 8,191,339 B2
• Filed: 02/19/2010
• Issued: 06/05/2012
• Est. Priority Date: 12/03/2002
• Status: Active Grant

• Current Assignee: Baxter Corporation Englewood (Baxter International Inc.)
• Original Assignee: FHT, Inc.
• Inventors: Tribble, Dennis, Osborne, Joel A., Khan, Abdul Wahid, Lefebre, Edward J.
• Primary Examiner(s): DESAI, HEMANT
• Application Number:
  US12/708,841
• Publication Number:
  US 20100217431A1
• Time in Patent Office: 837 Days
• Field of Search: 532/81, 532/87, 534/68, 534/71, 534/78, 534/85
• US Class Current: 53/281
• CPC Class Codes: A61J 1/10 Bag-type containers
• CPC Class Codes: A61J 1/20 Arrangements for transferring or mixing fluids, e.g. from vial to syringe
• CPC Class Codes: A61J 1/2096 Combination of a vial and a syringe for transferring or mixing their contents
• CPC Class Codes: A61J 2200/74 for weight
• CPC Class Codes: A61J 2205/10 Bar codes
• CPC Class Codes: A61J 2205/30 Printed labels
• CPC Class Codes: A61J 3/002 Compounding apparatus specially for enteral or parenteral nutritive solutions bottling liquids B67C
• CPC Class Codes: A61M 2207/00 Methods of manufacture, assembly or production
• CPC Class Codes: A61M 5/2448 comprising means for injection of two or more media, e.g. by mixing
• CPC Class Codes: B65B 3/003 Filling medical containers such as ampoules, vials, syringes or the like
• CPC Class Codes: B65B 7/2821 applying plugs or threadless stoppers for bottles or jars B67B1/04
• CPC Class Codes: B65C 3/06 Affixing labels to short rigid containers
• CPC Class Codes: B65C 3/26 Affixing labels to non-rigid containers, e.g. bottles made of polyethylene, boxes to be inflated by internal air pressure prior to labelling

Abstract

An automated medication preparation system for preparing a prescribed dosage of medication in a drug delivery device includes a plurality of stations for receiving, handling and processing the drug delivery device so that the prescribed dosage of medication is delivered to the drug delivery device and a transporting device that receives and holds more than one drug delivery device and moves the drug delivery devices in a controlled manner from one station to another station. The system is configured so that two or more separate drug delivery devices can be acted upon at the same time.

Claims

1. 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 tip cap having a base portion and a flange, the device comprising:

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

a gripper mechanism movable by the support frame including a pair of gripper arms at first and second locations, respectively, that are positionable between an open position and a closed position in which the base portion of the tip cap is securely held in contact therebetween during both removal of the tip cap from the empty syringe at the first location and during the subsequent replacement of the tip cap on the filled syringe at the second location, wherein the tip cap is released from the gripper mechanism between its removal and replacement after the tip cap is placed at the remote location;

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;

whereby the gripper mechanism is available for one or more operations between the removal and replacement of the tip cap while the tip cap remains at the remote location.

2. The automated device according to claim 1, wherein the gripping mechanism having the pair of gripper arms comprises:

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 the programmable controller and each of the first and second gripping devices moves in at least two directions contacts and holds the same tip cap.

3. The automated device according to claim 2, wherein the second automated gripping device is located at a different location than the first automated gripping device, the syringe being held in a fixed position as is advanced from the first automated gripping device to the second automated gripping device.

4. The automated device according to claim 2, further including a station where a plunger of the syringe is extended prior to filling the syringe at another station, the syringe being advanced to the station where the plunger is extended after the first automated gripping device removes the tip cap.

5. The automated device according to claim 4, further including an automated rotary device that receives and holds a plurality of syringes in a nested manner and is indexed to advance one syringe from one station to another station including stations where the first automated gripping device is located, the plunger is extended and the second automated gripping device is located.

6. The automated device according to claim 1, wherein each of the 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 gripper arms are in the closed position, the shaped cut outs define an opening that is sized to receive and hold the tip cap.

7. The automated device according to claim 1, wherein each of the first and second automated gripper arms is movable along an x axis and a y axis.

8. The automated device according to claim 1, wherein the plurality of drive actuators 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 gripper arm and a third control mechanism for controlling inward and outward movement of the gripper arm.

9. The automated device according to claim 8, 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.

10. The automated device according to claim 8, wherein each of the first and second automated gripper arms 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.

11. The automated device according to claim 10, 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.

12. The automated device according to claim 8, wherein the gripper arm 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 post for retainingly parking the tip cap, the post being separate from the gripping mechanism, the tip cap being inserted onto the post such that it stands upright thereon and is parked at the remote location and is free of contact with the gripping mechanism when parked at the remote location.

13. The automated device according to claim 12, further comprising a device for holding the syringe in an upstanding position while the gripper mechanism engages the tip cap, wherein the post that is formed as part of the support for receiving and holding the removed tip cap is located proximate the upstanding syringe, both the device that holds the syringe and the post being indexed to advance the syringe from one station to another station.

14. The automated device according to claim 1, further including an automated rotary device that receives and holds a plurality of syringes in discrete locations and is indexed to advance each syringe from one station to another station, the rotary device having an upstanding post for holding the removed tip cap as each syringe is advanced from one station to the next, each held syringe having a corresponding post for holding the tip cap that corresponds therewith.

15. The automated device according to claim 1, 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.

16. The automated device according to claim 1, wherein the gripper mechanism is operatively connected to a control unit that positions the gripper arms between the open and closed positions.

17. The automated device according to claim 1, wherein the sensor comprises a reflecting light emitting diode (LED).

18. The automated device according to claim 1, 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.

19. The automated device according to claim 1, 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.

20. The automated device according to claim 1, 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.

21. The automated device according to claim 1, wherein the support frame comprises a vertical base.

22. The automated device according to claim 1, further comprising a filling station, wherein the controller and sensor are configured such that if the sensor detects that the tip cap is not securely attached to a barrel of the syringe, 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 advanced, in an indexed manner, to the filling station and subjected to at least one device for automatically removing, parking the tip cap, filling the syringe and replacing the tip cap.

23. The automated device of claim 1, wherein the sensor is configured and located such that the sensor detects whether the tip cap is securely held between the gripper arms as the tip cap is both removed from the empty syringe and delivered to the remote location and as the tip cap is removed from the remote location and delivered to the filled syringe where it is placed thereon.

25. The automated device according to claim 1, wherein each gripper arm has a gripping section with a notch that receives the tip cap and has locating posts that ensure that the tip cap remains in a desired gripping position, the tip cap being disposed between a bottom face of the locating posts and an upper face of the gripping sections.

26. The automated device according to claim 1, further including an automated rotary device that receives and holds a plurality of syringes in a nested manner and is indexed to advance one syringe from one station to another station, the empty syringe with tip cap affixed thereto being introduced to the gripper mechanism while the syringe is nested on the rotary device.

24. The automated device according to clam 1, further including a device for holding the syringe in an upstanding position while the gripper mechanism contacts the tip cap and the remote location includes a post on which the tip cap is placed, the post being located adjacent the upstanding syringe, both the device that holds the syringe and the post being indexed in unison to advance the syringe from one station to another station.

27. An automated system including an automated first 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 first device being located at a first station and a fourth station comprising:

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

a gripper mechanism movable by the support frame 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 in contact therebetween during both removal of the tip cap from the empty syringe at the first station and during the subsequent replacement of the tip cap on the filled syringe at the fourth station;

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

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

wherein the system further includes;

a third station configured to fill the syringe;

a second station where a plunger of the syringe is extended prior to filling the syringe at the third station, the syringe being advanced to the second station after the automated first device removes the tip cap at the first station; and

an automated rotary device that receives and holds a plurality of syringes in a nested manner and is indexed to advance one syringe from one station to another station including the first station, the second station, and the third station, the tip cap being removed and replaced while the syringe is nested within the rotary device and the plunger being extended while the syringe is nested within the rotary device.

28. An automated system including an automated first 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 first device being located at a first station and a fourth station comprising:

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

a gripper mechanism movable by the support frame 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 in contact therebetween during both removal of the tip cap from the empty syringe at the first station and during the subsequent replacement of the tip cap on the filled syringe at the fourth station;

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

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

wherein the system further includes;

a third station configured to fill the syringe;

a second station where a plunger of the syringe is extended prior to filling the syringe at the third station, the syringe being advanced to the second station after the automated first device removes the tip cap at the first station; and

an automated rotary device that receives and holds a plurality of syringes in a nested manner and is indexed to advance one syringe from one station to another station including the first station, the second station, and the third station, the tip cap being removed and replaced while the syringe is nested within the rotary device and the plunger being extended while the syringe is nested within the rotary device.

29. 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 tip cap having a base portion and a flange, the device comprising:

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

a gripper mechanism movable by the support frame including a pair of gripper arms at first and second locations, respectively, that are positionable between an open position and a closed position in which the base portion of the tip cap is securely held in contact therebetween during both removal of the tip cap from the empty syringe at the first location and during the subsequent replacement of the tip cap on the filled syringe at the second location, wherein the tip cap is released from the gripper mechanism between its removal and replacement after the tip cap is placed at the remote location, the tip cap being held at the remote location independent from and free of contact with the gripper mechanism;

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;

whereby the gripper mechanism is available for one or more operations between the removal and replacement of the tip cap while the tip cap remains at the remote location.