Robotic tray loader system, method and apparatus

In a system for transferring groups of containers from one location to another, a loading station including a transfer mechanism for continuously delivering rows of containers from the transfer station to a tray loading station. A device at the tray loading station is included for cycling the tray in a predetermined controlled sequence to receive rows of containers delivered by the transfer mechanism and to position them in a compact array in the tray.

FIELD OF THE INVENTION 
The present invention relates to a system, method and apparatus for 
transferring containers, such as vials for pharmaceutical products, from 
one location to another in a high speed processing environment. More 
specifically, the invention relates to improvements in automatic handling 
of vials and transferring them from an accumulator location and depositing 
them in a predetermined orientation in trays for further processing, such 
as sterilization. 
BACKGROUND OF THE INVENTION 
Automatic handling systems for vials containing pharmaceutical products are 
not new per se. There are a variety of known systems and apparatus for 
high speed, automated processing of vials for pharmaceutical products. For 
example, The West Company, Incorporated, assignee of the present 
application, has a line of equipment for automatic capping of 
pharmaceutical vials and equipment for washing and sterilizing vials at 
high production rates. However, there are still some operations which are 
done manually. For example, there is a line of test equipment for checking 
particulate matter and seal integrity where the vials are manually 
positioned in place during the test operation. In other instances, it may 
be necessary to manually place vials in special trays for certain 
processes, such as lyophilization or sterilization. 
SUMMARY OF THE INVENTION 
With the foregoing in mind, it is an object of the present invention to 
provide a system, method and apparatus for automatically transferring 
vials from one location to another at high speeds. For example, the 
present invention has useful application in those instances where, in the 
past, vials were manually transferred and placed in special trays for 
sterilization. Thus, the present invention consists broadly of an infeed 
conveyor system where vials are delivered single file to an accumulator 
station and then grouped in predetermined numbers by a series of 
cooperating, selectively adjustable, escapement mechanisms which can be 
selectively oriented to vary the number of vials segregated into groups. 
The system further includes a so-called "CAMBOT pick and place assembly" 
having a plurality of vial transfer mechanisms operable to pick up and 
transfer groups of vials from one location to another. CAMBOT is the 
trademark for a commercially available robotic motion machine which can be 
control led to produce predetermined axial and rotational repetitive 
cycles. 
More specifically, the transfer mechanism comprises a turret and a 
plurality of radially outwardly directed, circumferentially spaced, 
gripper assemblies selectively positionable between open and closed 
positions to deliver rows of vials from a vial pickup station to a tray 
loading station in a predetermined controlled sequence as determined by 
the CAMBOT assembly. 
In accordance with another feature of the present invention, the infeed 
assembly includes means for controlling grouping of the vials to provide a 
staggered array of rows of vials in the tray and thereby maximizes 
utilization of the tray space. More specifically, the escapement gate 
nearest the transfer mechanism has an escapement pin which locates the 
front vial in a group to be transferred at a further distance from the 
actuating mechanism than a dead stop in the infeed trackway. Thus, in the 
operation of the system, when the escapement pin is retracted, the vials 
entering the transfer station engage the dead stop every other cycle. This 
produces the desired staggered orientation of groups of vials delivered to 
the tray. 
The system further includes a novel servo motor driven tray conveyor which 
advances a properly oriented empty tray to a "home" or vial loading 
position. As a row of vials is delivered to the tray, the tray conveyor 
reverses whereby the compactor blade of a pusher assembly engages the row 
of vials into a compact array against the front wall of the empty tray, or 
against the row of vials previously compacted. The tray conveyor continues 
to move in a reverse direction until resistance is sensed by the compactor 
blade signaling advance movement of the conveyor a predetermined distance 
to accommodate the next row of vials. The displaced distances traveled by 
the tray conveyor are accurately measured by an encoder and this 
information is delivered to a programmable logic circuit (PLC) to control 
proper cycling of the tray conveyor for vials of different types and 
sizes. 
When a predetermined number of vials are delivered to the tray in rows in 
the manner described above to fill a given tray, the programmable logic 
circuit (PLC) signals the tray conveyor to discharge the filled tray from 
the tray loading station and advance the next empty tray to a home 
position at the loading station. 
The filled trays are advanced by the tray conveyor until they rest on the 
rollers of the discharge conveyor. The filled trays are then free to coast 
gently down the discharge conveyors until engaging a stop. 
The system also includes sensors associated with the discharge conveyor for 
signaling certain conditions which may interfere with normal operation. 
For example, two filled trays on the discharge conveyor produce an audible 
signal alerting the operator to move a tray but does not interfere with 
normal automatic operation of the system. If three filled trays are on the 
discharge conveyor, the system is automatically shut down to prevent 
damage to trays and vials. Additionally there are sensors along the tray 
conveyor adjacent the tray loading station to insure proper orientation 
and seating of the tray on the conveyor which in turn insures proper 
loading of the vials in the tray in the manner described above.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
For ease of understanding the method, system and apparatus of the present 
invention, it is desirable first to consider the broad details and 
arrangement of the system and how they function. Thus, the overall system, 
which is best shown and illustrated in FIGS. 1 and 2, comprises a vial 
infeed conveyor assembly C.sub.i which directs vials B to a vial transfer 
station S.sub.t. A series of escapement mechanisms M.sub.e located along 
the path of the infeed conveyor assembly C.sub.i function to segregate 
groups of vials B into rows B.sub.1, B.sub.2, B.sub.n of a preselected 
number of vials for pick-up and transfer in a group or row by a CAMBOT 
pick and place assembly 62. The CAMBOT assembly 62 has a rotating turret 
60 and a plurality of arms A, in the present instance four (4), having 
gripping jaw mechanisms operable between open and closed positions (See 
FIGS. 17A and 17B). The turret 60 rotates and reciprocates in a 
predetermined timed cycle to effect transfer of vials B from the vial 
transfer station S.sub.t to the tray loading station S.sub.l. The system 
further includes a tray conveyor C.sub.t controlled to automatically 
position trays T at the loading station S.sub.l and cycle during the 
loading process to effect loading the rows of vials in the tray T in a 
compact nested array as shown in FIG. 20. Filled trays T are then moved to 
a discharge conveyor C.sub.d for manual processing. 
There is shown in FIGS. 8 and 9 a tray configuration having a particular 
design providing certain operating functions in the system and apparatus 
of the present invention. The tray T is of a generally rectangular shape 
having opposing side walls 10 and 12 and front wall 14. The end of the 
tray T opposite the front wall is open. The open end of tray T is designed 
to receive a detachable end wall manually positioned in place after the 
tray has been filled in the manner described in more detail hereafter. 
The tray T further includes downwardly depending fingers adjacent the front 
wall 14 and open rear end of the tray T. The front fingers are designated 
20A and those adjacent the open rear end of the tray are designated 20B. 
As shown in FIG. 14, the fingers engage in a space between the guide rails 
21A and 21B of the tray conveyor C.sub.t to stabilize the tray during 
movement along the conveyor. The fingers also trigger sensors to insure 
that the trays entering the tray loading station S.sub.l are in the proper 
attitude and disposition on the conveyor. The legs 20B are staggered as 
shown in FIG. 9 and the legs 20A are aligned in a transverse plane or 
direction so that the sensor discriminates forward and reverse positioning 
of the tray T on the conveyor. 
Considering now the specific structural details and arrangement of the 
system and apparatus broadly described above and considering first the 
details of the vial infeed conveyor assembly C.sub.i, these details are 
best shown FIGS. 4, 5 and 10-12 inclusive. As illustrated, the vial infeed 
conveyor C.sub.i comprises an endless belt 22 which moves in an endless 
path around a drive sprocket 34 and driven sprocket 36 by means of a motor 
and gear reduce M.sub.1. The drive sprocket 34 is connected to the motor 
and gear reducer by chain 32. The vial conveyor C.sub.i includes a pair of 
upstanding elongated guide rails 37 defining a pathway P for presenting 
vials B in single file to the transfer station S.sub.t. The guide rails 37 
are mounted on blocks 38 which determine the width of the vial pathway P. 
When it is desired to change the width of the path P to accommodate vials 
of different diameter, the blocks 38 are changed. The blocks 38 are 
pre-gauged for vials of different diameters. 
Escapement mechanism means M.sub.e are provided along the vial pathway P 
for controlling the number of vials delivered to the vial transfer station 
S.sub.t in groups. In the present instance, the escapement mechanisms 
M.sub.e comprise three solenoid operated gates 40, 42 and 44 located along 
the pathway P, having actuating pins 40A, 42A and 44A respectively, 
positionable in an extended position through the vial pathway P and a 
retracted position out of the pathway P permitting vials to move freely on 
the conveyor. With reference to FIG. 13, middle gate 42 is adjustable and 
is fixed along the pathway P in a predetermined position determined by the 
length of the gripper jaws J of the transfer mechanism to segregate a 
first group of vials B.sub.1. Gate 40 is adjustable along the pathway P 
and is fixed relative to the gate 42 to determine the second group of 
vials B.sub.2. The innermost gate 44 is mounted in a fixed position. The 
actuating pin 44A of gate 44 mounts a spring biased first stop 44B. A 
second adjustable spring biased stop 44, staggered relative to stop 44B, 
is mounted on rail 37 and functions as a dead stop. This system functions 
to permit alternate staggering of the rows of vials delivered to the tray 
T and facilitates nesting of the rows in a manner shown in FIG. 20. For 
example, with pin 44A in an extended position as shown in solid lines in 
FIG. 12, the lead vial of the row B.sub.1 is stopped in the solid line 
position shown. When the pin 44A is retracted, the lead vial of the next 
row B.sub.2 is in the dotted line position engaging dead stop 44. 
Operatively associated with the gates are two sensors 46 and 48. Sensor 46 
senses the presence of the row of vials B.sub.1 at the transfer station 
S.sub.t and is operative to condition actuation of the transfer mechanism 
R. Sensor 48 senses the rows of vials B.sub.2 preparing to move into the 
transfer station S.sub.t. Considering the operation of the gates briefly, 
gate 42 is normally closed and gate 40 is normally open permitting vials B 
to flow into the pathway P between the gates to accumulate vials in rows 
B.sub.1 and B.sub.2 in the manner described. When a predetermined number 
of vials forming a first group B.sub.1 enters the pre-transfer region of 
pathway P, gate 40 closes, and simultaneously gate 42 opens to allow group 
B.sub.1 to move to the transfer station S.sub.t. This operation is a 
continuous process, the gates 40 and 42 flip-flopping in the manner 
described to feed vials in predetermined groups to the transfer station 
S.sub.t. 
The vials forming row B.sub.1 at the transfer station S.sub.t, accumulated 
in the manner described above, are now ready for pick-up and transfer to 
the tray T. The structural details and arrangement of the transfer 
mechanism is best illustrated in FIGS. 3-5 and 13-16, inclusive. The 
transfer mechanism comprises a generally elongated cylindrical turret 60 
adapted for rotational and axial displacement by means of a CAMBOT 
mechanism 62 which is a commercially known robotic actuating mechanism. 
Turret 60 mounts four circumferentially equi-spaced gripper arms 64A-64D. 
Each gripper arm includes an elongated arbor 66 and a pair of pivotally 
mounted gripper jaws 68 which engage under the bottle finish in the manner 
shown in FIG. 17A during a transfer cycle. The in turned ends of the 
gripper jaws 68 are preferably covered with a flexible material, such as 
plastic, to prevent damage to the vials B. The jaws 68 are pivoted between 
open and closed positions by actuators comprising a solenoid 70, scissor 
linkage 72 and return springs 74. The spring 74 normally maintains the 
jaws in a closed position. Energization of the solenoid 70 extends the 
scissor linkage 72 and opens the jaws 68 against the bias of the springs 
74. The jaws 68 are disposed in an open or closed position depending on 
whether the transfer mechanism is in a vial pick-up mode or vial discharge 
mode. For example, when an arm 64A overlies the group of vials B.sub.1 at 
the transfer station, the jaws 68A are open and when the turret 60 is in 
its lower limit position, the jaws 68A close under the finish of the vials 
of group B.sub.1. The jaws 68A remain in a closed position as the turret 
60 is raised and rotated to position the group of vials B.sub.1 over the 
tray T at the tray loading station S.sub.l. The jaws 68A open and release 
vials B.sub.1 when the arm 64A reaches its lower limit position to deposit 
them in the tray T. 
The repetitive actuating cycle of the turret 60 is as follows. The "home" 
position of the turret 60 is in the upper limit position shown in FIG. 5 
with arm 64A aligned with the infeed conveyor C.sub.i. The turret 60 
includes four proximity sensors 80A-80D for sensing the position of the 
four (4) arms 64A-64D relative to the "home" position. The CAMBOT assembly 
62 also includes a series of proximity sensors 82A, 82B and 82 arranged in 
a dial-like configuration and actuated sequentially by means of a rotating 
flag 84 mounted on the output shaft of the CAMBOT 62. Accordingly, when 
the CAMBOT positions the turret 60 in the "home" position, flag 84 
registers with the sensor 82A. Sensor 82B energizes solenoid 70A and 70D 
for gripper arm assemblies 64A and 64D to position the jaws 68A and 68D in 
an open position and the solenoid 70B and 70 for gripper arm assemblies 
64B and 64 remain de-energized and therefore the jaws 68B and 68 are 
closed. The CAMBOT device cycle then continues moving the turret 60 
downwardly to its lower limit position and in this position the flag 84 
registers with sensor 82B. In this position, sensor 82B signals solenoid 
70A of arm 64A to close gripper jaws 68A embracing the row of vials 
B.sub.1 at the transfer station S.sub.t for delivery. The solenoid 70B for 
gripper arm assembly 64B simultaneously is energized to release vials at 
the tray delivery station S.sub.l. The CAMBOT mechanism 62 then returns 
turret 60 to its upper limit position moving flag 84 to register with 
proximity sensor 82 initiating cycling of the vial tray conveyor C.sub.t 
and rotating turret 60 through 90.degree.. 
The tray loading section of the apparatus is best illustrated in FIGS. 3, 
4, 7 through 9, and 14. Considering first the broad details of the tray 
loading section, there is provided an endless tray conveyor C.sub.t 
powered by a servo motor M.sub.s which can be selectively actuated 
forwardly or rearwardly through a programmable logic circuit (PLC). In a 
typical cycle of operation and with respect to the various schematic views 
of FIGS. 19A- 19G, inclusive, the conveyor C.sub.t delivers an empty tray 
T to the home tray loading position so that a first row of vials B.sub.1 
to be deposited in the tray T can be positioned in the tray with a 
predetermined clearance from the front wall 14 as illustrated in FIG. 19A. 
A pusher assembly 400 includes a compactor blade 420 after a row of vials 
B.sub.1 is deposited on the tray, the conveyor C.sub.t is actuated 
rearwardly and in so doing the row of vials B.sub.1 is urged by the blade 
420 against the front wall 14 of the tray T as shown in FIG. 19B. Movement 
of the tray T rearwardly displaces the pivotally mounted rocker arms 402 
of the pusher assembly which signals reversal of the conveyor C.sub.t and 
initiates a forward displacement a predetermined increment to create a 
space for the next row of vials B.sub.2 to be delivered as illustrated in 
FIGS. 19 and 19D. When the next row of vials B.sub.2 is delivered, they 
are staggered relative to the previous row B.sub.1 in the manner described 
previously and as shown in FIG. 20. 
Accordingly, when the conveyor C.sub.t is reversed to compact the vials 
just delivered, the pusher bar urges them into a nested configuration with 
the first row B.sub.1. (See FIGS. 19E and 20). The cycle of filling, 
discharging, and compacting the rows B.sub.1 and B.sub.2 in the manner 
described above continues until a tray T is completely filled as shown in 
FIG. 20. When the tray has been filled to capacity as measured by the PLC, 
the conveyor C.sub.t is actuated forwardly to deliver the full tray T to a 
discharge position and advances the next adjacent empty tray T to the 
"home" position as shown in FIG. 19A. The filled tray is advanced to a 
downwardly inclined discharge ramp and moves slowly by gravity to a stop 
position on the discharge conveyor C.sub.d either engaging the ultimate 
stop at the end of the discharge conveyor or a previously filled tray 
ahead of it. These filled trays are then redirected or removed manually by 
operators. 
Considering now the tray conveyor section more specifically, (See FIGS. 
7-9, FIG. 14, and FIGS. 19A-20) the tray conveyor C.sub.t comprises two 
endless belts 200A and 200B of a predetermined width so that trays 
straddle the conveyor in the manner shown in FIG. 8. The inner surface of 
the belts have a toothed configuration to mesh with drive sprockets 202, 
204 and provide a nonslip, high speed accurate positioning of trays 
necessary for accurate positioning and loading of vials in the manner 
described above. Drive sprockets 202 and 204 are mounted on a common shaft 
206 which is connected by a belt 208 via pulleys 210 and 212 to the drive 
shaft 214 of a servo motor M.sub.s. As illustrated in FIG. 7, the shaft 
206 is connected to an encoder 220 by means of a flexible coupling 222. 
The conveyor belts 200A and 200B are connected by a series of spaced 
transversely extending tray retention cleats 230 and 232 which are spaced 
apart a predetermined distance equal to the length of a tray T as shown in 
FIGS. 8 and 9 so that a tray positioned between the cleats 230 and 232 
nests snugly in place on the conveyor belts. Note that one of the cleats 
232 has a beveled or angled edge 232A to facilitate positioning of the 
tray T and the cleats 230 are shaped to define a shelf 230A adjacent the 
rear open end of a tray T so that the last row of vials B can be deposited 
in spaced relationship to the previous row prior to being nested by the 
pusher bar. (See, for example, FIGS. 19D or 19G and 20) 
Proper positioning of the trays T on the conveyor C.sub.t is important to 
insure the controlled sequence of operations described above. To this end, 
there are a number of sensors positioned along the conveyor C.sub.t for 
determining proper seating and orientation of the trays T on the conveyor. 
For example, a so-called high tray, or unseated, sensor 300 is located 
upstream of the tray "home" position at a predetermined small height above 
the upper edge of the side wall of a correctly seated tray T on the 
conveyor. Accordingly, if a tray T is cocked or out of position, it is 
detected by the sensor 300 and it stops operation of the conveyor C.sub.t 
and provides visual indicia to the operator indicating the tray T next to 
arrive at the "home" position is not fully seated and therefore would 
cause a problem during the filling operation. A sensor 302 reads the 
profile of the tray legs 20B. Accordingly, if a given tray T is flush on 
the conveyor but reversed, the sensor 302 will bypass the tray T and 
advance the conveyor until a correctly positioned tray is in the "home" 
position. 
A sensor in the form of an infrared emitter 304 and detector 306 is located 
adjacent the tray loading station S.sub.l to sense the front edge of a 
tray coming into the "home" position. Interruption of the beam halts 
advance movement of the conveyor to correctly position a tray T in the 
proper "home" position and initiates operation of the CAMBOT device 62 to 
begin delivery of vials in the manner described above. 
A series of proximity sensors are located along the discharge conveyor 
C.sub.d (See FIG. 2). A first proximity sensor 308 senses a filled tray T 
abutting the stop 309 at the end of the discharge ramp and a second 
proximity sensor 310 senses a second filled tray T abutting the first 
filled tray. The proximity sensor 310 is connected to an audible alarm to 
signal the operator that a filled tray T needs to be removed from the 
discharge ramp. This sensor 310 simply initiates an audible alarm and does 
not interfere with the filling operation of the trays. The system includes 
a third proximity sensor 312 upstream from the first two sensors. If the 
discharge ramp is filled to this point, the third proximity sensor 312 
will shut down further operation until filled trays are removed. 
Consider now the specific details and operation of the spring biased 
pivotally mounted pusher arm assembly 400 (See FIGS. 3 and 4). The spring 
biased pusher bar assembly 400 comprises a pair of vertically extending 
rocker arms 402, pivotally mounted at their lower ends, as at 404, to the 
lower deck plate 406 of the main support table 408. The upper terminal 
ends of the rocker arms 402 are tied together by a cross plate 410 forming 
a generally inverted "U" shaped bracket. Arms 414, forming an extension of 
rocker arms 402, pass through slots 416 in the upper deck 418 of the main 
support table 408. Arms 414 straddle the tray conveyor. The upper terminal 
ends of the arms 414 have rearwardly extending portions 414A which 
pivotally support the compactor blade 420. The compactor blade 420 has a 
width slightly less than the inside width of the tray T and is centered to 
work within the side walls of the tray. The entire pusher bar assembly 400 
just described is forwardly biased by means of a spring 426 into 
engagement with an adjustable proximity sensor 428 mounted on a pedestal 
430 secured to the lower deck 406. 
In operation, when the tray conveyor C.sub.t is driven in a reverse 
direction, the lead edge of the compactor blade 420 engages the vials 
B.sub.1 opposing their oncoming motion causing the vials B.sub.1 to slide 
along the tray bottom until the vials contact the end wall 14 of the tray 
or into nested contact with a previously compacted row of vials (See FIGS. 
3 & 19A-19G). Continued rearward motion of the tray conveyor C.sub.t then 
causes the spring biased pusher arm assembly 400 to move away from the 
proximity sensor 428 signaling an immediate change in direction of 
conveyor C.sub.t to reposition the tray T in a precisely calculated 
position providing the necessary clearance for the next loading sequence 
(See FIG. 19A-19G). The spring biased pusher bar assembly 400 returns to 
its forwardly biased position against sensor 428. 
The direction of travel of the tray conveyor C.sub.t is generated by the 
servo motor. How far the tray conveyor travels in either direction is 
determined by the diameter of the vials to be run and has been programed 
into the programmable logic circuit (PLC), and the exact distance of 
travel of the tray conveyor in either direction is measured by the 
encoder. 
Consider now the operation of the method, apparatus and system of the 
present invention in processing vials B from a vial pickup or transfer 
station S.sub.t to a tray loading station S.sub.l. As noted above, the 
system and apparatus of the present invention are designed to handle a 
wide variety of vials which differ in volume, diameter and height. 
Accordingly, the type of vial to be run is first entered into the 
programmable logic circuit (PLC) on the keyboard of the console and these 
conditions allow for automatic operation of the various mechanisms for 
processing vials in the manner described. Vials B to be run are randomly 
oriented at an accumulator station and are delivered by a vial conveyor 
C.sub.i single file to a vial pickup station S.sub.t. Vial trays are 
positioned on the tray conveyor C.sub.t. Gates 40 and 42 are positioned 
along the conveyor pathway P to separate the vials B in discrete groups 
B.sub.1, B.sub.2 for pickup by the transfer arms in successive cycles of 
the operation of the turret. For example, the length of the gripper blades 
of the pickup arms determines the number of vials B in the groups B.sub.1, 
B.sub.2. The position of gate 42 from the end stop 44B determines the 
number of vials B in group B.sub.1, and the position of gate 40 from gate 
42 determines the number of vials in group B.sub.2. 
The apparatus is now set for automatic operation and thus the main power 
switch S.sub.p on the console is engaged by the operator. The conditions 
for automatic operation include positioning of the turret 60 so that the 
arm 64A is aligned with the infeed conveyor C.sub.i, and in this position 
the gripper jaws 68A are in an open position. It is noted that sensors 
80A-80D, spaced about the periphery of the turret assembly 60, sense the 
position of each arm through 360.degree. of rotation. Thus, when arm 64A 
overlies the vial infeed conveyor C.sub.i, the turret 60 is in the "home" 
position and the CAMBOT device 62 is at the first phase of an actuating 
cycle. In this position, flag 84 on the CAMBOT output shaft registers with 
proximity sensor 82A. 
The vial conveyor C.sub.i is now energized to deliver vials to the vial 
pick-up station S.sub.t. When sensor 46 is activated, it signals the 
presence of a row of vials B.sub.1 at the vial pick-up station S.sub.t. 
Tray conveyor T is energized to position an empty tray T in a "home" 
position at the loading station S.sub.l. The tray T is in the home 
position when the lead edge of the tray intercepts the beam from emitter 
304 and detector 306. 
With a predetermined number of vials B at the pick-up station, the turret 
60 is in its upper limit position with the arm 64A overlying the group of 
vials B.sub.1, and, as noted above, an empty tray T is located in the 
"home" position at the loading station S.sub.l. The CAMBOT device 62 
initiates an operation cycle (See FIGS. 18A, 18B, and 18). In a typical 
cycle, the turret arm 64A moves downwardly with the gripper jaws 68A in an 
open condition and the solenoid 70A is energized to maintain the jaws 68A 
in an open position against the bias of springs 74. When the turret 
descends to its lower limit position, the gripper jaws 68A close to 
embrace group B.sub.1 at the pick-up station S.sub.t. In this position the 
CAMBOT device 62 is moved through 90.degree. of its cycle and flag 84 of 
the CAMBOT device is aligned with proximity sensor 82B to signal the 
de-energization of solenoid 70A which closes gripper jaws 68A. 
Simultaneously, solenoids 70B and 70D are energized to spread gripper jaws 
68B and 68D of arms 64B and 64D to an open position. 
The cycle continues whereby the turret 60 is moved upwardly to its upper 
limit position to carry the first row of vials B.sub.1 securely by the 
gripper jaws 68A. When the turret 60 reaches its upper limit position, the 
CAMBOT device 62 has moved through 225.degree. of its cycle. In this 
position, flag 84 is aligned with sensor 82 which initiates cycling and 
positioning of the tray T to receive the row of vials B.sub.1 with a 
predetermined clearance with the front wall 14 of the tray T. The turret 
then rotates through 90.degree. to reposition the arm 64A over the tray 
conveyor C.sub.t. During this portion of the cycle the next group of vials 
B.sub.2 are advanced to the pick-up station S.sub.t. 
Again with reference to FIGS. 18A-18 inclusive, the first cycle of the 
CAMBOT device 62 ends with the turret 60 in the upper limit position 
wherein the arm 64A now extends transversely and overlies the empty tray T 
disposed in the "home" position at the loading station S.sub.l. In this 
position, the row of vials B.sub.1 is suspended above the tray T and the 
vials B are held firmly by the gripper jaws 68A. In this position the arm 
64D now overlies the vial infeed conveyor C.sub.i at the vial pick-up 
station S.sub.t, solenoid 70D being energized and thus the gripper jaws 
68D are in a open position. The flag 84 of the CAMBOT device 62 again 
registers with proximity sensor 82A. 
During the second cycle of the CAMBOT device 62, the group of vials B.sub.1 
is delivered to the tray T at the loading station S.sub.l. Thus, at the 
start of the second cycle, the turret 60 of the CAMBOT device 62 moves 
downwardly from its upper limit position lowering the initial row of vials 
B.sub.1 into the tray at the tray loading station S.sub.l (See FIG. 19A). 
It is noted that the stroke of the turret 60 between upper and lower limit 
positions is a constant and that the upper surface of the infeed conveyor 
belt C.sub.i is co-planar with the upper face of the tray bottom on the 
tray conveyor C.sub.t. This insures that vials B delivered to the tray T 
are positioned gently in the tray by reason of the fact that the bottom 
face of the tray and the infeed conveyor C.sub.i are located in a common 
plane. 
When flag 84 aligns with sensor 82B, the solenoid 70A is energized which 
moves gripper jaws 68A to an open position releasing the initial row of 
vials B.sub.1 to the tray T at the tray loading station S.sub.l. 
Simultaneously, solenoid 70D is de-energized, closing jaw 68D to engage 
the second row of vials B.sub.2 at the vial pick-up station S.sub.t. As 
the CAMBOT device 62 continues in its cycle, the turret 60 moves upwardly 
to its upper limit position and during this part of the cycle, solenoid 
70A de-energizes closing gripper jaws 68A of arm 64A at the midpoint of 
its travel to the upper limit position. 
When the turret 60 reaches its upper limit position, flag 84 is aligned 
with sensor 82 which initiates the compacting and advancing motions of the 
tray conveyor C.sub.t. The turret 60 rotates 90.degree. to position arm 64 
over the vial pick-up station S.sub.t with gripper jaws 68 in an open vial 
engaging position and the arm 64D is positioned transversely relative to 
the tray T and tray conveyor C.sub.t with its gripper jaws 68D closed 
supporting the second row of vials B.sub.2. 
The cycling, or motions, of the conveyor C.sub.t and tray T supported 
thereon are controlled to precisely position the tray T under an arm of 
the turret 60 such that the closed end wall 14 of the tray T is advanced 
far enough to provide the necessary clearance for the opening of the 
gripper blades within the tray T during discharge of a row of vials to the 
tray T. This is defined as the "home" position of the tray T. Further, the 
compactor blade 420 of the pusher assembly 400 is adjusted for vials of 
different diameters to provide a small clearance and thereby avoid 
interference with the descending vials as they enter the tray T in the 
manner illustrated in FIG. 19A. The length of the tray T and the diameter 
of the vials being processed are programed into the PLC along with a 
factor to compensate for apparent change in vial diameter due to nesting 
of the vials in the staggered configuration. (See FIG. 20). 
With the tray then in the "home" position, a first row of vials B.sub.1 
delivered to the tray T, and the turret 60 in its upper limit position, 
the flag 84 is aligned with the sensor 82C and initiates the tray conveyor 
C.sub.t, vial compacting and advance sequence. More specifically, the 
servo motor M.sub.S drives the tray conveyor C.sub.t in a reverse 
direction so that the lead edge of the compactor blade 420 engages the 
vials B.sub.1 and arrests the vials B.sub.1 as the tray is moving 
rearwardly until the vials engage the front wall 14 of the tray T. At this 
point the compactor blade 420 is pivoted rearwardly initiating a forward 
drive of the conveyor, and the tray T is repositioned forward of the 
initial "home" position a predetermined controlled distance providing 
sufficient clearance for discharging the next row of vials B.sub.2 and 
successive rows thereafter. The clearance for the next row of vials 
B.sub.2 is shown in FIG. 19C. The travel distance of the conveyor C.sub.t 
forwardly and rearwardly is measured by the encoder 220 so that the PLC 
stores the available tray length remaining for the additional rows of 
vials. In this regard the rearward travel distance of the conveyor C.sub.t 
and the tray T is slightly greater for each of the compacting strokes 
after the first row of vial B.sub.1 is compacted due to the nesting of the 
vials caused by the staggering of the rows of vials (See FIG. 20). 
The apparatus continues to cycle to deliver vials B to the tray in the 
manner described above until the tray is full. The last row of vials 
B.sub.n is deposited on the L-shaped cleat 230A and the compacting stroke 
slides this row into engagement with the previously compacted row of vials 
thereby completely filling the tray (See FIG. 20). Thus the apparatus and 
method of the present invention insure complete filling of the trays 
thereby maximizing handling of vials. 
The filled tray condition is preprogrammed into the PLC for each of the 
various vial types shown on the keyboard. Accordingly, when a tray is 
completely full, the PLC initiates advance of the tray conveyor C.sub.t to 
discharge the full tray to the discharge C.sub.d station and advances an 
empty tray T into the "home" position. The compactor blade 420, which is 
pivotally mounted, is merely pushed upwardly out of the way by the end 
wall 14 of the new advancing empty tray T.sub.2 and falls back into 
operative position behind the end wall 14 when the new tray arrives at the 
"home" position. 
The operation of the robotic tray loader described above continues 
automatically as long as vials are delivered to the vial pick-up station 
S.sub.t and empty trays T are supplied to the home position at the tray 
loading station S.sub.l. It is noted that various safety interlocks are 
provided to trouble shoot the various operations and are displayed on the 
main console as lights or audible alarms. Also, emergency stop buttons are 
provided on the operator side of the loading table 408. 
As noted above, the system, method and apparatus of the present invention 
are adapted for vials of different diameters and heights. To accommodate 
vials of different heights, the turret 60 is adjustable in a vertical 
direction relative to the conveyors. The vertical adjustment means is best 
shown in FIG. 13. Thus the turret 60 includes a base 500 mounted on the 
main shaft 510 of the CAMBOT device 62. The base having an elongated 
upstanding post 501 and a telescoping sleeve 502 slideably mounted on the 
post 501 which carries the arm assemblies 64A-64D. The sleeve 502 and arm 
assemblies 64A-64D are vertically moveable relative to the post 501 by 
means of a jack screw assembly 504 and adjustment wheel 506. The CAMBOT 
device 62 has locating pins 512 which engage in openings in the base 500 
of the turret 60. As illustrated, the CAMBOT device 62 includes a shroud 
505 having a plurality of slip rings 506 providing contacts for energizing 
the solenoids 70A-70D, inclusive. FIG. 13 shows the turret 60 in its lower 
limit positions (solid lines) and its upper limit positions (broken 
lines). 
Even though particular embodiments of the invention has been illustrated 
and described herein, it is not intended to limit the invention, and 
changes and modifications may be made therein with the scope of the 
following claims.