Presorter holding system and method for automated prescription fulfillment

• US 9,846,566 B1
• Filed: 03/29/2017
• Issued: 12/19/2017
• Est. Priority Date: 03/29/2017
• Status: Active Grant

• Current Assignee: Humana Incorporated
• Original Assignee: Humana Incorporated
• Inventors: Kapadia, Atin, Mahar, Michael, Payyapilly, Anu, Bihnam, Andrew
• Primary Examiner(s): Randazzo, Thomas
• Application Number:
  US15/473,135
• Time in Patent Office: 265 Days
• CPC Class Codes: B65G 1/1373 for fulfilling orders in warehouses
• CPC Class Codes: B65G 1/1378 the orders being assembled on fixed commissioning areas remote from the storage areas
• CPC Class Codes: B65G 2201/0261 Puck as article support
• CPC Class Codes: B65G 2203/0216 Codes or marks on the article
• CPC Class Codes: B65G 2203/0233 Position of the article
• CPC Class Codes: B65G 2203/044 Optical
• CPC Class Codes: B65G 2203/046 RFID
• CPC Class Codes: B65G 43/08 Control devices operated by article or material being fed, conveyed or discharged and controlling the discharging devices B65G47/42
• CPC Class Codes: B65G 47/69 the articles being accumulated temporarily accumulating articles during transit B65G47/261
• CPC Class Codes: B65G 47/82 Rotary or reciprocating members for direct action on articles or materials, e.g. pushers, rakes, shovels means for pushing glass articles onto a conveyor C03B9/453
• CPC Class Codes: G06F 7/06 Arrangements for sorting, selecting, merging, or comparing data on individual record carriers
• CPC Class Codes: G06F 7/08 Sorting, i.e. grouping record carriers in numerical or other ordered sequence according to the classification of at least some of the information they carry by merging two or more sets of carriers in ordered sequence G06F7/16
• 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
• CPC Class Codes: Y10T 156/1744 Means bringing discrete articles into assembled relationship
• CPC Class Codes: Y10T 156/1768 Means simultaneously conveying plural articles from a single source and serially presenting them to an assembly station

Abstract

An automated method and system for a conveyor holding system for holding vials of a multi-vial order in a holding pattern until all vials of the order have been filled by an automatic pill counter. The system uses RFID information to divert vials off the conveyor into the conveyor holding loop if all vials of the multi-vial order have not been filled. The system is adapted to divert the vials of the multi-vial order out of the holding loop when all vials of the multi-vial order have been filled.

Claims

1. A vial conveyor holding system placed after a bank of automatic pill counters in an automatic prescription fulfillment system, the vial conveyor holding system comprising:

a first inbound conveyor lane for transporting vials to the bank of automatic pill counters;

a first outbound conveyor lane for transporting vials from the bank of automatic pill counters after the vials are filled with pills;

a conveyor holding loop adjacent to the first outbound conveyor lane for holding vials in a holding pattern;

a first mechanical diverter for pushing vials off the first outbound conveyor lane onto the conveyor holding loop;

a first RFID reader for sensing RFID information from RFID tags near the first mechanical diverter;

a second mechanical diverter for pushing vials off the conveyor holding loop onto the first outbound conveyor lane;

a second RFID reader for sensing RFID information from RFID tags near the second mechanical diverter;

a first control processing system, the control processing system programmed with instructions executing on the processing system for;

     1) receiving RFID information from the first and second RFID readers;

     2) sending a first control signal to the first mechanical diverter to push a first vial off the first outbound conveyor lane and onto the conveyor holding loop if the first vial is part of a first multi-vial order and if all vials of the first multi-vial order have not been filled by an automatic pill counter;

     3) sending a second control signal to the second mechanical diverter to push the first vial off the conveyor holding loop and onto the first outbound lane when all of the vials of the first multi-vial order have been filled by an automatic pill counter.

2. The vial conveyor holding system of claim 1, further comprising:

a first photoelectric sensor placed near the first mechanical diverter for sensing the presence of vials passing by the first photoelectric sensor;

a second photoelectric sensor placed near the second mechanical diverter for sensing the presence of vials passing by the second photoelectric sensor;

wherein the control processing system is programmed with instructions executing on the processing system for;

     1) receiving signals from the first and second photoelectric sensor; and

     2) timing the sending of the first control signal to the first mechanical diverter to push the first vial onto the conveyor holding loop based on the signal received from the first photoelectric sensor;

     3) timing the sending of the second control signal to the second mechanical diverter to push the first vial off the conveyor holding loop and onto the first outbound lane based on the signal received from the second photoelectric sensor.

3. The vial conveyor holding system of claim 1, wherein the first and second mechanical diverters are rods wherein each rod has a mechanical member for pushing vials.

4. The vial conveyor holding system of claim 1, wherein the first and second mechanical members are each comprised of a motor and a rotating member for pushing vials.

5. The vial conveyor holding system of claim 1, wherein the conveyor holding loop is a conveyor adapted to move vials in a loop holding pattern.

6. The vial conveyor holding system of claim 5, wherein the loop is in an oval or circular shape.

7. The vial conveyor holding system of claim 1, wherein the control processing system is programmed with instructions executing on the processing system for:

1) saving information regarding each of the vials in the first multi-vial order in a table stored in the system;

     2) saving in the table for each of the vials in the first multi-vial order, RFID information, prescription information, and information on whether the vial has been filled by an ATC machine.

8. The vial conveyor holding system of claim 1, wherein the system is adapted to divert vials from the conveyor holding loop to an exceptions processing station after a predetermined period of time.

9. A vial conveyor holding system placed after a bank of automatic pill counters in an automatic prescription fulfillment system, the vial conveyor holding system comprising:

a first inbound conveyor lane for transporting vials to the bank of automatic pill counters;

a first outbound conveyor lane for transporting vials from the bank of automatic pill counters after the vials are filled with pills;

a conveyor holding loop adjacent to the first outbound conveyor lane for holding vials in a holding pattern;

a first mechanical diverter for pushing vials off the first outbound conveyor lane onto the conveyor holding loop;

a first RFID reader for sensing RFID information from RFID tags near the first mechanical diverter;

a second mechanical diverter for pushing vials off the conveyor holding loop onto the first outbound conveyor lane;

a second RFID reader for sensing RFID information from RFID tags near the second mechanical diverter;

a first photoelectric sensor placed near the first mechanical diverter for sensing the presence of vials passing by the first photoelectric sensor;

a second photoelectric sensor placed near the second mechanical diverter for sensing the presence of vials passing by the second photoelectric sensor;

a first control processing system, the control processing system programmed with instructions executing on the processing system for;

     1) receiving RFID information from the first and second RFID readers;

     2) sending a first control signal to the first mechanical diverter to push a first vial off the first outbound conveyor lane and onto the conveyor holding loop if the first vial is part of a first multi-vial order and if all vials of the first multi-vial order have not been filled by an automatic pill counter;

     3) sending a second control signal to the second mechanical diverter to push the first vial off the conveyor holding loop and onto the first outbound lane when all of the vials of the first multi-vial order have been filled by an automatic pill counter;

     4) receiving signals from the first and second photoelectric sensor; and

     5) timing the sending of the first control signal to the first mechanical diverter to push the first vial onto the conveyor holding loop based on the signal received from the first photoelectric sensor;

     6) timing the sending of the second control signal to the second mechanical diverter to push the first vial off the conveyor holding loop and onto the first outbound lane based on the signal received from the second photoelectric sensor.

10. The vial conveyor holding system of claim 9, wherein the first and second mechanical diverters are rods wherein each rod has a mechanical member for pushing vials.

11. The vial conveyor holding system of claim 9, wherein the first and second mechanical members are each comprised of a motor and a rotating member for pushing vials.

12. The vial conveyor holding system of claim 9, wherein the conveyor holding loop is a conveyor adapted to move vials in a loop holding pattern.

13. The vial conveyor holding system of claim 12, wherein the loop is in an oval or circular shape.

14. The vial conveyor holding system of claim 9, wherein the control processing system is programmed with instructions executing on the processing system for:

1) saving information regarding each of the vials in the first multi-vial order in a table stored in the system;

     2) saving in the table for each of the vials in the first multi-vial order, RFID information, prescription information, and information on whether the vial has been filled by an ATC machine.

15. A vial conveyor holding system placed after a bank of automatic pill counters in an automatic prescription fulfillment system, the vial conveyor holding system comprising:

a first inbound conveyor lane for transporting vials to the bank of automatic pill counters;

a first outbound conveyor lane for transporting vials from the bank of automatic pill counters after the vials are filled with pills;

a conveyor holding loop adjacent to the first outbound conveyor lane for holding vials in a holding pattern;

a first mechanical diverter for pushing vials off the first outbound conveyor lane onto the conveyor holding loop;

a first RFID reader for sensing RFID information from RFID tags near the first mechanical diverter;

a second mechanical diverter for pushing vials off the conveyor holding loop onto the first outbound conveyor lane;

a second RFID reader for sensing RFID information from RFID tags near the second mechanical diverter;

a first control processing system, the control processing system programmed with instructions executing on the processing system for;

     1) receiving RFID information from the first and second RFID readers;

     2) saving information regarding each of the vials in a first multi-vial order in a table stored in the system;

     3) saving in the table for each of the vials in the first multi-vial order, RFID information, prescription information, and information on whether the vial has been filled by an ATC machine;

     4) sending a first control signal to the first mechanical diverter to push a first vial off the first outbound conveyor lane and onto the conveyor holding loop if the first vial is part of the first multi-vial order and if all vials of the first multi-vial order have not been filled by an automatic pill counter;

     5) sending a second control signal to the second mechanical diverter to push the first vial off the conveyor holding loop and onto the first outbound lane when all of the vials of the first multi-vial order have been filled by an automatic pill counter.

16. The vial conveyor holding system of claim 15, further comprising:

a first photoelectric sensor placed near the first mechanical diverter for sensing the presence of vials passing by the first photoelectric sensor;

a second photoelectric sensor placed near the second mechanical diverter for sensing the presence of vials passing by the second photoelectric sensor;

wherein the control processing system is programmed with instructions executing on the processing system for;

     1) receiving signals from the first and second photoelectric sensor; and

     2) timing the sending of the first control signal to the first mechanical diverter to push the first vial onto the conveyor holding loop based on the signal received from the first photoelectric sensor;

     3) timing the sending of the second control signal to the second mechanical diverter to push the first vial off the conveyor holding loop and onto the first outbound lane based on the signal received from the second photoelectric sensor.

17. The vial conveyor holding system of claim 15, wherein the first and second mechanical diverters are rods wherein each rod has a mechanical member for pushing vials.

18. The vial conveyor holding system of claim 15, wherein the first and second mechanical members are each comprised of a motor and a rotating member for pushing vials.

19. The vial conveyor holding system of claim 15, wherein the conveyor holding loop is a conveyor adapted to move vials in a loop holding pattern.

20. The vial conveyor holding system of claim 19, wherein the loop is in an oval or circular shape.