Patent Abstract:
An automated method for dispensing pharmaceuticals particularly tablets and capsules, and other small discrete objects, includes: receiving prescription information, selecting a container, labeling the container, dispensing the tablets or capsules into the labeled container, applying a closure to the filled, labeled container, and offloading the container to a designated location. Preferably, the tablets are dispensed with high speed dispensing bins that employ forced air to agitate and singulate the tablets. The other functions within the system are typically carried out at stations designed to offer speed, flexibility and precision to the dispensing operation.

Full Description:
RELATED APPLICATION  
       [0001]     This application claims priority from U.S Provisional Patent Application Ser. No. 60/380,402, filed 14 May 2002, the disclosure of which is hereby incorporated herein in its entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention is directed generally to the dispensing of prescriptions of pharmaceuticals, and more specifically is directed to the automated dispensing of pharmaceuticals.  
       BACKGROUND OF THE INVENTION  
       [0003]     Pharmacy generally began with the compounding of medicines which entailed the actual mixing and preparing of medications. Heretofore, pharmacy has been, to a great extent, a profession of dispensing, that is, the pouring, counting, and labeling of a prescription, and subsequently transferring the dispensed medication to the patient. Because of the repetitiveness of many of the pharmacist&#39;s tasks, automation of these tasks has been desirable.  
         [0004]     Some attempts have been made to automate the pharmacy environment. Different exemplary approaches are shown in U.S. Pat. No. 5,337,919 to Spaulding et al. and U.S. Pat. Nos. 6,006,946; 6,036,812 and 6,176,392 to Williams et al. These systems utilize robotic arms to grasp a container, carry it to one of a number of bins containing tablets (from which a designated number of tablets are dispensed), carry it to a printer, where a prescription label is applied, and release the filled container in a desired location. Tablets are counted and dispensed with any number of counting devices. Drawbacks to these systems typically include the relatively low speed at which prescriptions are filled and the absence in these systems of securing a closure (i.e. a lid) on the container after it is filled.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention is directed to an automated system and method for dispensing pharmaceuticals, particularly tablets and capsules, and other small discrete objects. Embodiments of the system and method are capable of receiving a patient&#39;s prescription information, selecting a container, labeling the container, dispensing the tablets or capsules into the labeled container, applying a closure to the filled, labeled container, and offloading the container to a designated location. Preferably, the tablets are dispensed with high speed dispensing bins that employ forced air to agitate and singulate the tablets. The other functions within the system are typically carried out at stations designed to offer speed, flexibility and precision to the dispensing operation.  
         [0006]     As a first aspect, embodiments of the invention are directed to a method of dispensing solid pharmaceutical items of substantially identical size and configuration from a bulk of such solid pharmaceutical items stored in a housing. The method comprises the steps of: providing a singulating bin comprising a hopper and a dispensing channel fluidly connected thereto, the dispensing channel defining a flow path; applying a forwardly-directed jet into the dispensing channel; passing a series of solid pharmaceutical items in single file from the hopper into the dispensing channel; accelerating the solid pharmaceutical items in the dispensing channel with the forwardly-directed jet; counting the number of solid pharmaceutical items that pass a predetermined point in the dispensing channel; comparing the number of solid pharmaceutical items that have passed the predetermined point with a predetermined number; and applying a rearwardly-directed jet into the dispensing channel after a predetermined number of solid pharmaceutical items have passed the predetermined point to draw any additional items in the dispensing channel back into the hopper. This method can dispense pharmaceutical items rapidly and accurately.  
         [0007]     As a second aspect, embodiments of the present invention are directed to an apparatus for dispensing solid pharmaceutical items, comprising: a frame; a container dispensing station attached to the frame; a labeling station attached to the frame; a labeling carrier configured to grasp and transport a container from the container dispensing station to the labeling station; a dispensing station having a plurality of bins that receive and dispense solid pharmaceutical items; a dispensing carrier that receives a labeled container from the labeling carrier and transports the labeled container to the dispensing station for filling with solid pharmaceutical items from one of the bins; and a controller operatively connected with and controlling the operation of the container dispensing station, the labeling station, the labeling carrier, the dispensing station, and the dispensing carrier. Such an apparatus can dispense filled, labeled pharmaceuticals rapidly and accurately.  
         [0008]     As a third aspect, embodiments of the present invention are directed to an apparatus for dispensing solid pharmaceutical items, comprising a dispensing station comprising a plurality of bins for storing the items, each of the bins containing items of substantially identical size and configuration, and at least some of the bins containing items that differ in size and/or composition from the items contained in others of the housings. Each of the bins includes a dispensing outlet on one side that dispenses items, a replenishment opening on a side thereof opposite the dispensing outlet, and an electronic unit that monitors the counting of items traveling through the dispensing outlet. The bins are mounted on a frame such that the dispensing outlets face an access region within the frame and the replenishment openings face away from the frame. A dispensing carrier is configured to transport containers to be filled with the items. The dispensing carrier is positioned within the access region. A controller controls the operation of the dispensing carrier. In this configuration, bins can be replenished without removing them from the frame or interfering with the operation of the apparatus as it dispenses from other bins.  
         [0009]     Those skilled in this art will recognize that many of the individual stations within the apparatus described above and combinations thereof also represent additional embodiments of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]      FIG. 1  is a flow chart illustrating an embodiment of a method according to the present invention.  
         [0011]      FIG. 2  is a perspective view of a pharmaceutical tablet dispensing system according to the present invention.  
         [0012]      FIG. 3  is a cutaway view of the system of  FIG. 2  illustrating the container dispensing station, the labeling carrier, the dispensing carrier, and the closure dispensing station.  
         [0013]      FIG. 4  is a top view of the container dispensing station of the system of  FIG. 2  showing the cup holding a container in the donating position.  
         [0014]      FIG. 5  is a top view of the container dispensing station of  FIG. 4  showing the cup holding a container in the receiving position.  
         [0015]      FIG. 6  is an enlarged perspective view of the container dispensing station of  FIG. 4 .  
         [0016]      FIG. 7  is a perspective view of the gripping unit of the label carrier of the system of  FIG. 2  with the fingers thereof rotated to a radially inward position and the unit itself in a raised position above the container-dispensing cup.  
         [0017]      FIG. 7A  is a section view of the gripping unit of  FIG. 7 .  
         [0018]      FIG. 8  is a perspective view of the gripping unit of  FIG. 7  with the fingers thereof in the process of rotating radially outwardly and the unit itself in a lowered position into a container in the container dispensing cup.  
         [0019]      FIG. 9  is a perspective view of the gripping unit of  FIG. 7  with the fingers thereof rotated to a radially outward position and the unit itself rising with the container above the container dispensing cup.  
         [0020]      FIG. 10  is a bottom view of the gripping unit of  FIG. 7  with the fingers thereof in rotated to a radially inward position.  
         [0021]      FIG. 11  is a bottom view of the gripping unit of  FIG. 7  with the fingers thereof rotated to an intermediate position.  
         [0022]      FIG. 12  is a bottom view of the gripping unit of  FIG. 7  with the fingers thereof in rotated to a radially outward position.  
         [0023]      FIG. 13  is a schematic top view of the labeling station of the system of  FIG. 2  prior to the application of a label on a container.  
         [0024]      FIGS. 14-16  are schematic top views of the labeling station of  FIG. 13  during the application of a label on a container as the container is held and rotated by the gripping unit of  FIG. 7 .  
         [0025]      FIG. 17  is an enlarged perspective view of the transfer of a container from the labeling carrier of  FIG. 7  to the dispensing carrier of the system of  FIG. 2 .  
         [0026]      FIG. 18  is an enlarged perspective view of the lower carriage and the grip unit of the dispensing carrier of  FIG. 17  illustrating that the lower carriage can be moved vertically and horizontally and that the grip unit can be rotated about two axes.  
         [0027]      FIG. 19  is an enlarged perspective view of a dispensing bin employed in the system of  FIG. 2 .  
         [0028]      FIGS. 20A and 20B  are section views of the dispensing bin of  FIG. 19  showing how the size of the dispensing channel of the dispensing bin can be adjusted.  
         [0029]      FIG. 21  is a greatly enlarged side view of the dispending bin of  FIG. 19  showing how the height of the dispensing channel can be adjusted.  
         [0030]      FIG. 22  is a bottom view of the dispensing bin of  FIG. 19  showing how the width of the dispensing channel can be adjusted.  
         [0031]      FIG. 23  is an enlarged exploded view of the dispensing bin of  FIG. 19  showing its interconnection with the low pressure manifold, the high pressure conduit, and the electronics mounted on the frame of  FIG. 3 .  
         [0032]      FIG. 23A  is a schematic diagram of the controller and three exemplary connector boards from the frame and three exemplary bin-controlling circuit boards.  
         [0033]      FIG. 23B  is a schematic diagram of another embodiment of the controller of the system of  FIG. 2 .  
         [0034]      FIG. 24  is an enlarged assembled view of the dispensing bin of  FIG. 19  with the low pressure manifold, the high pressure conduit, and the electronics mounted on the frame.  
         [0035]      FIG. 25  is an enlarged side view of the securing member of the dispensing bin of  FIG. 19  showing how the securing member locks the dispensing bin in place on the frame.  
         [0036]      FIG. 26  is an enlarged section view of the assembled dispensing bin and frame of  FIG. 24  with tablets loaded into the bin.  
         [0037]      FIG. 27  is an enlarged section view of the assembled dispensing bin and frame of  FIG. 24  with tablets being agitated by low pressure air flowing upwardly through the bin.  
         [0038]      FIG. 28  is an enlarged section view of the assembled dispensing bin and frame of  FIG. 24  with high pressure air being applied to the dispensing channel, such that tablets are drawn therein in single file in a lengthwise orientation.  
         [0039]      FIG. 29  is an enlarged section view of the assembled dispensing bin and frame of  FIG. 24  with a desired number of tablets dispensed into the container.  FIG. 30  is an enlarged perspective view of the closure dispenser of the closure dispensing station of the system of  FIG. 2 .  
         [0040]      FIG. 31  is an enlarged perspective view of the closure dispenser of  FIG. 30  with the closure bin removed.  
         [0041]      FIG. 32  is a greatly enlarged section view of a closure unable to be oriented with the closure dispenser of  FIG. 30 .  
         [0042]      FIG. 33  is a greatly enlarged section view of a closure able to be oriented with the closure dispenser of  FIG. 30 .  
         [0043]      FIG. 34  is a bottom perspective view of the closure dispenser of  FIG. 30 .  
         [0044]      FIG. 35  is an enlarged side perspective view of the closure holder of the system of  FIG. 2  with a filled container in a lower position.  
         [0045]      FIG. 36  is an enlarged side perspective view of the closure holder of  FIG. 35  with the container raised to engage a closure.  
         [0046]      FIG. 37  is an enlarged side perspective view of the closure holder of  FIG. 35  with the filled, closed container lowered. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0047]     The present invention will now be described more fully hereinafter, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numbers refer to like elements throughout. Thicknesses and dimensions of some components may be exaggerated for clarity. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.  
         [0048]     As described above, the invention relates to a system and process for dispensing pharmaceuticals. The process is described generally with reference to  FIG. 1 . The process begins with the identification of the proper container, tablets or capsules and closure to be dispensed based on a patient&#39;s prescription information (Box  20 ). A container of the proper size is dispensed at a container dispensing station (Box  22 ), then grasped and moved to a labeling station (Box  24 ). The labeling station applies a label (Box  26 ), after which the container is transferred to a transport system and moved to a tablet dispensing station (Box  28 ), from which the designated tablets are dispensed in the designated amount into the container (Box  30 ). The filled container is then grasped again and moved to a closure dispensing station (Box  32 ), where a closure of the proper size has been dispensed (ox  34 ). The filled container is secured with a closure (Box  36 ), then transported to an offload station and offloaded (Box  38 ).  
         [0049]     A system that can carry out this process is illustrated in  FIGS. 2-37  and designated broadly therein at  40 . Referring first to  FIGS. 2 and 3 , the system  40  includes a support frame  44  for the mounting of its various components. The illustrated support frame  40  includes a base  46  that rests on an underlying surface. Four uprights  48  extend vertically from the base  46  and define an internal cavity  45  within which the operable components of the system  40  generally reside. A pair of top rails  50  are attached to the upper ends of the uprights  48 , and two cross-members  52  span the distance between the front and rear ends of the top rails  50 . Top, intermediate and bottom arches  54 ,  55 ,  56  are mounted to extend from the front surfaces of the front uprights  48 . The frame  44  also includes two lower rails  51  that extend between pairs of uprights  48  well below the top rails  52 , and further includes a pair of intermediate rails  53  that are mounted in vertical alignment between two uprights  48  below one of the top rails  52 .  
         [0050]     Those skilled in this art will recognize that the frame  40  illustrated herein is exemplary and can take many configurations that would be suitable for use with the present invention. The frame  40  provides a strong, rigid foundation to which other components can be attached at desired locations, and other frame forms able to serve this purpose may also be acceptable for use with this invention.  
         [0051]     Referring again to  FIGS. 2 and 3 , the system  40  generally includes as operative stations a controller  42 , a container dispensing station  58 , a labeling station  60 , a tablet dispensing station  62 , a closure dispensing station  64 , and an offloading station  66 . Containers, tablets and closures are moved between these stations with two different conveying devices: a labeling carrier  68  and a dispensing carrier  70 . Each of the operative stations and the conveying devices is described in detail below.  
         [0052]     The controller  42 , which is mounted to and below the top arch  54 , controls the operation of remainder of the system  40 . In some embodiments, the controller  42  will be operatively connected with an external device, such as a personal or mainframe computer, that provides input information regarding prescriptions. In other embodiments, the controller  42  may be a stand-alone computer that directly receives manual input from a pharmacist or other operator. An exemplary controller is a conventional microprocessor-based personal computer.  
         [0053]     Referring now to  FIGS. 4-6 , the container dispensing station  58 , which is mounted to the bottom arch  56 , comprises a plurality of tubes  80  oriented generally vertically and about a common axis of rotation. In the illustrated embodiment, three sets of tubes  80  of different sizes are illustrated; the ensuing discussion is equally applicable to each.  
         [0054]     A bottom plate  82  is fixed to the bottom ends of the tubes  80  and a top plate  84  fixed to the top ends of the tubes  80 . Each of the bottom and top plates  82 ,  84  have apertures that correspond to the ends of the tubes  80 . The tubes  80  and bottom and top plates  82 ,  84  are free to rotate as a unit about the axis of rotation Al and are driven by a motor or other rotary drive unit attached to the bottom plate  82  (the motor is not shown). A sorting plate  86  or other member is fixed to the lower arch  56  below and parallel to the bottom plate  82 . The sorting plate  86  includes a slotted opening  87  at one edge. As is shown in  FIGS. 5 and 5 , a cup  88  or other receiving member is pivotally attached to lower surface of the sorting plate  86  such that it may move between a receiving position below the opening  87  ( FIG. 5 ) and a donating position beyond the perimeter of the sorting plate  86  ( FIG. 4 ) (pivoting of the cup  88  is controlled by the controller  42  through a second motor (not shown)).  
         [0055]     Prior to operation, the tubes  80  within each set are filled with containers of similar size, with each set of tubes  80  housing containers of different sizes. Filling can be carried out by loading the containers in a preferred orientation through an orientation tube  84   a  (see  FIG. 2 ), which has an opening  85   a  with a downward extending finger  86   a  that ensure that the containers are loaded with their open ends facing upwardly. The containers travel through the orientation tube  84  through the openings in the top plate  84  in an upright orientation with their open ends facing upwardly, so that they are vertically stacked within the tubes  80 . In some embodiments, each set of tubes  80  is filled with different sizes of containers, while in other embodiments, individual tubes  80  within the same set of tubes may be filled with different sizes of containers.  
         [0056]     In operation, the controller  42  signals the container dispensing station  58  that a container of a specified size is desired. The bottom and top plates  82 ,  84  rotate until a tube  80  that houses a container is positioned above the opening  87 . At this point, the cup  88  is in its receiving position beneath the opening  87  ( FIG. 5 ). The lowermost container drops downwardly through the opening  87  and into the cup  88 . The controller  42  then signals the cup  88  to pivot to its donating position ( FIGS. 4 and 6 ), wherein the container can be grasped by the labeling carrier  68 . The cup  88  includes a support finger  89  trailing the receptacle portion of the cup  88  to support containers remaining in the tubes  80  when the cup  88  is in the donating position.  
         [0057]     Those skilled in this art will appreciate that other container dispensing apparatus may be employed with the present invention. For example, the containers may be presented for grasping in a horizontal disposition, or the dispensing apparatus may include a conveyor unit that presents the containers one at a time for grasping. The skilled artisan will recognize additional embodiments that would be suitable for use with the inventive system.  
         [0058]     From the container dispensing station  58 , the container is moved to the labeling station  60 ; this movement is carried out by the labeling carrier  68  (see  FIGS. 3 and 7 - 12 ). The labeling carrier  68  comprises an upright support member  91  fixed to the base of the frame  40 , a carriage  92  attached to and moveable vertically on the support member  91 , a swing arm  94  attached thereto that pivots about a vertical axis A 2 , and a gripping unit  96  attached to the free end of the swing arm  94 . Both the vertical movement of the carriage  92  and the pivoting of the swing arm  94  and gripping unit  96  can be induced with conventional robotic techniques that need not be described in detail herein.  
         [0059]     The gripping unit  96  has a body portion  98 , a base  102  rotatably attached to the body portion  98  for rotation about an axis A 3 , a clutch mechanism  101  attached to the body portion  98  and coupled to the base  102 , a plurality of fingers  104  (three are illustrated herein) that are rotatable and eccentrically mounted to the base  102  and extend downwardly therefrom generally parallel to each other, and a motor  100  attached to the body portion  98  and coupled to the fingers  104 . Each finger  104  is fixed to a finger shaft  105 , which in turn is fixed to a planet gear  106  such that, as the planet gear  106  rotates, so must the attached finger  104 . Each planet gear  106  is attached to the base  102  in such a way as to be able to rotate freely relative thereto. A sun gear  107  is rotatably mounted onto the base  102  and can freely rotate in relation thereto about the axis A 3 . Each planet gear  106  engages the sun gear  107 , so that when the sun gear  107  rotates in relation to the base  102 , the planet gears  106  also rotate relative to the base  102  about a respective axis A 4 , A 5 , A 6 . A motor shaft  108  is fixed to the sun gear  107  along the axis A 3  and is coupled to the motor  100  via a motor gear train  109 .  
         [0060]     Each finger  104  has an arcuate outer surface  104   a  that defines a portion of a circle, such that, when all of the fingers  104  are rotated to a radially inward position ( FIG. 7  and  10 ), the outer surfaces  104   a  of the fingers  104  form a stepped vertical cylinder, with their vertices  104 b adjacent to one another. The fingers  104  can be rotated about their eccentric axes of rotation A 4 , A 5 , A 6  ( FIG. 11 ) so that their vertices  104 b move radially outwardly from each other; rotation in this manner expands the circle defined by the radially outwardmost portions of the outer surfaces  104   a  of the fingers  104 . (see  FIGS. 8, 9  and  12 ). In operation, after the container of the desired size has been dispensed in one of the cups  88  as discussed above, the controller  42  signals the labeling carrier  68  to grasp the container. The carriage  92  slides on the support member  91 , thereby moving the swing arm  94  to a height such that the lower ends of the fingers  104  are above the upper edge of the container. Also, the swing arm  94  pivots relative to the carriage  92  such that the fingers  104  are positioned directly over the container. At this point, the fingers  104  are rotated radially inwardly ( FIGS. 7 and 10 ) to a retracted position. The carriage  92  then descends, which action lowers the fingers  104  into the cavity of the container. The motor  100  then exerts a torque on the sun gear  107  via the motor gear train  109  and the motor shaft  108 , thereby causing the sun gear  107  to exert a torque on the planet gears  106  and a torque on the base  102  (via the planet gears  106  and finger shafts  105 ). Because the clutch  101  restrains the base  102  from rotating (via a pulley  101   a  and a belt  101   b ), the planet gears  106  rotate about axes A 4 , A 5 , A 6  in response to this torque, causing the fingers  104  to turn and expand radially outward (see  FIGS. 8 and 11 ) until they contact the inside surface of the container (see  FIGS. 9 and 12 ). At this point, the container wall resists further expansion of the fingers  104 , thereby inducing an opposing torque on the base  102  transmitted via the fingers  104 , finger shafts  105 , and planet gears  106 . Once this opposing torque exceeds the breaking torque of the clutch  101 , the base  102  and container—now held by the fingers  104 —rotates about the axis A 3 . The clutch  101  continues to exert a restraining torque on the base  102  as the base  102  rotates. The fingers  104  continue to exert pressure on the inside of the container (as explained above) as the base  102  rotates, thereby inducing the container to rotate and enabling the fingers  104  to lift the container from the cup  88 . The controller  42  signals the carriage  92  to rise on the support member  91 . As this occurs, the fingers  104  lift and carry the container from the cup  88 , and the container continues to rotate relative to the body portion  98  due to the rotation of the base  102 .  
         [0061]     Other techniques for grasping and moving the container from the container dispensing station  58  will be apparent to those skilled in this art. For example, the gripping fingers may take a different configuration (e.i., they may not form a cylinder when rotated inwardly). As another example, gripping fingers may be used that grip the outer surface of the container. Alternatively, suction may be employed to temporarily grasp and move the container.  
         [0062]     Once the labeling carrier  68  has retrieved the container from the cup  88 , it carries the container to the labeling station  60  (see  FIGS. 3 and 13 - 16 ). The labeling station  60  includes a printer  110  that is controlled by the controller  42 . The printer  110 , which is mounted to one side of the base  46 , prints and presents an adhesive label that is to be affixed to the container. The labeling station  60  also includes a wiping device, such as the brush  112  illustrated in  FIG. 8 , that is positioned adjacent to the exit port  114  of the printer  110 .  
         [0063]     Returning to the operation of the system  40 , once the container has been grasped and is being rotated by the labeling carrier  68 , it is moved (under the direction of the controller  42 ) to the exit port  114  of the printer  110  through appropriate translation of the carriage  92  on the support member  91  and pivoting of the swing arm  94  relative to the carriage  92  ( FIG. 13 ). Once the printed label has exited the exit port  114 , the labeling carrier  68  presents the rotating container to the label ( FIG. 13 ); the rotation of the container enables the wiping device to smoothly apply the label to the container (augmented by the brush  112 —see  FIGS. 14-16 ).  
         [0064]     Those skilled in this art will appreciate that other structures and components for affixing a printed label to a container may also be employed with the present invention. For example, the container may be transferred to pinch rollers located at the exit port  114 .  
         [0065]     After the container has been labeled, the labeling carrier  68  moves to a transfer position (through appropriate movements of the carriage  92 , swing arm  94 , and body portion  98 , as directed by the controller  42 ) and transfers the labeled container to the dispensing carrier  70  ( FIGS. 3, 17  and  18 ). The dispensing carrier  70  includes an upper carriage  120  that slides upon a rail  122  extending between the cross-members  52 , a rail  124  that extends downwardly from the carriage  120 , a lower carriage  126  that slides vertically along the rail  124 , and a grip unit  128  that is mounted on the lower carriage  126  via horizontally disposed circular tracks  130  that revolve around the lower carriage  126 . The grip unit  128  includes a traveler unit  132  that is mounted to the tracks  130 , an axle  134  that is rotatably mounted in and extends from the traveler unit  132 , and a gripping mechanism  136  that is attached to and is rotatable with the axle  134 . The gripping mechanism  136  has two jaws  138  that can confront each other and exert clamping force on an object (such as a container of the type discussed herein). Notably, the jaws  138  have a curved portion  139  that assists in gripping the cylindrical container. Also, the jaws  138  may be configured such that they compress the container only to a desired torque level (I with a clutch mechanism, or with a sensor that detects a predetermined current level for the drive motor) in order to prevent crushing of the container, or such that they compress only to predetermined positions selected to match the sizes of the different containers used with the system  40 .  
         [0066]     The dispensing carrier  70  has the capability of moving the gripping mechanism  136  (and, in turn, an object grasped therein) to designated locations within the cavity  45  of the frame  44 . Movement from end to end within the cavity  45  (i.e., toward and away from the arches  54 ,  55 ,  56 ) is accomplished by inducing movement of the upper carriage  120  on the rail  122 . Vertical movement is accomplished by inducing movement of the lower carriage  126  on the rail  124 . The grip unit  128  may also revolve around the rail  124  about an axis A 7  through revolution of the tracks  130  around the carriage  126 . The gripping mechanism  136  may rotate relative to the traveler unit  132  about an axis A 8  defined by the axle  134 . Induction and control of these movements may be achieved through conventional robotic techniques that need not be described in detail herein. The skilled artisan will also appreciate that other components for grasping and maneuvering a container may also be employed with the present invention.  
         [0067]     Returning to operation of the system  40 , transfer of the labeled container from the labeling carrier  68  to the dispensing carrier  70  is achieved by the controller  42  directing the dispensing carrier  70  to move the gripping mechanism  136  to a position in which the jaws  138  can clamp onto the outer surface of the container as it is presented by the labeling carrier  68 . Preferably, the position for transfer is proximate to the printer  110  and the tablet dispensing station  62 . The controller  42  first signals the dispensing carrier  70  to close the jaws  138  onto the outer surface of the container, then directs the labeling carrier  68  to retract the fingers  104  to their radially inward positions so that the container is held only by the jaws  138 . The fingers  104  are then withdrawn from the container (through either upward movement of the fingers  104  by the labeling carrier  68  or downward movement of the labeled container by the dispensing container  70 ), and the labeled container is ready to be filled with tablets.  
         [0068]     Filling of labeled containers with tablets is carried out by the tablet dispensing station  62  (see  FIGS. 2 and 19 - 29 ). The tablet dispensing station  62  comprises a plurality of tablet dispensing bins  150 , each of which holds a bulk supply of individual tablets (typically the bins  150  will hold different tablets). The dispensing bins  150 , which are typically substantially identical in size and configuration, are organized in an array mounted on the intermediate rails  53  of the frame  44 , and each has a dispensing channel  154  with an outlet that faces generally in the same direction, to create an access region for the dispensing carrier  70 . The identity of the tablets in each bins is known by the controller  42 , which can direct the dispensing carrier  70  to transport the container to the proper bin  150 . In some embodiments, the bins  150  may be labeled with a bar code or other indicia to allow the dispensing carrier  70  to confirm that it has arrived at the proper bin  150 .  
         [0069]     The dispensing bins  150  are configured to singulate, count, and dispense the tablets contained therein, with the operation of the bins  150  and the counting of the tablets being controlled by the controller  42 . Some embodiments may employ the controller  42  as the device which monitors the locations and contents of the bins  150 ; others may employ the controller  42  to monitor the locations of the bins, with the bins  150  including indicia (such as a bar code or electronic transmitter) to identify the contents to the controller  42 ; in still other embodiments the bins  150  may generate and provide location and content information to the controller  42 , with the result that the bins  150  may be moved to different positions on the frame  42  without the need for manual modification of the controller  42  (i.e., the bins  150  will update the controller  42  automatically).  
         [0070]     Any of a number of dispensing units that singulate and count discrete objects may be employed; however, dispensing units that rely upon targeted air flow and a singulating nozzle assembly, such as the devices described in co-pending U.S. patent application Ser. No. 09/934,940, filed Aug. 22, 2001 and entitled DEVICE TO COUNT AND DISPENSE ARTICLES and in U.S. Provisional Application No. 60/306,782, filed Jul. 20, 2001 for DEVICE TO COUNT AND DISPENSE ARTICLES, are preferred (these applications are hereby incorporated herein by reference in their entireties). Bins of this variety may also include additional features, such as those described below.  
         [0071]     Referring now to  FIGS. 19 and 23 - 29 , the bins  150  can be described generally as having a tablet-filled hopper  153  through which air flows and agitates the tablets contained therein, and the aforementioned dispensing channel  154  through which the tablets are dispensed one at a time. Suction can be applied to the channel  154  through a forwardly-directed jet  155 ; a rearwardly-directed jet  156  is also included that can reverse the motion of tablets within the channel  154 . The jets  155 ,  156  are controlled by the controller  42 , which initiates forward air flow in response to a customer order and activates rearward air flow in response to the passage of a certain quantity of tablets through in the dispensing channel  154  (as detected by a counting sensor  154   a  located in the dispensing channel  154 ). Alternatively, the jets  155 ,  156  may be controlled by a local controller unique to each bin  150  (as described in some detail below). The bins  150  can filled or replenished with tablets via access from a pivoting door  180  located at the upper rear portion of the bin  150 . Notably, the location of the door  180  opposite the outlet of the dispensing channel  154  enables an operator to replenish the bin  150  without disconnecting it from the frame  44  or interfering with the dispensing from this or another bin  150 . Also, the pivoting of the lower end portion of the door  180  and the inclusion of side walls  180 a causes an open door  180  to form a funnel-like configuration, which configuration can facilitate pouring of pharmaceuticals into the bin  150 .  
         [0072]     Referring now to  FIGS. 20A through 22 , the bins  150  may include components that permit the entry to the dispensing channel  154  to be adjusted in size to complement the size and configuration of the tablet to be dispensed. This can be achieved through a stationary wall  160 , a moveable wall  161 , a moveable ceiling  162  and a moveable floor  163  that form the entry to (and in some instances the perimeter of) the dispensing channel  154 . In the illustrated embodiment, the stationary wall  160  is a portion  151   a  of the housing  151  of the bin  150 . The stationary wall  160  also forms a portion of a recess  301  that extends inwardly into the housing  151 . The ceiling  162  is part of a ceiling unit  302  that fits within the recess  301 . The ceiling unit  302  also includes a vertical panel  304  extends downwardly from a lateral edge of the ceiling  162 . The vertical panel  304  includes two apertures and an engagement projection  306  that engages a slot in a wall of the recess  301 . Also, an adjustment knob  320  and attached threaded shank  322  insert through a threaded nut  324  attached to the vertical panel  304 ; the knob  320  is held in place within a recess in the housing  151 . The moveable wall  161  is part of a moveable wall unit  308  that includes front and rear panels  310 ,  312  that extend transversely from front and rear portions of the moveable wall  161 . Two posts  314  extend from the moveable wall  161  and pass through the apertures of the vertical panel  304  of the ceiling unit  302  into elongated slots  316  of the housing. A front projection  318  extends beyond the front panel  310  and is received in a slot  319  in the housing. The moveable floor  163  is part of a floor unit  326  that also includes a front portion  328  with a slot  330  that receives the front projection  318  of the moveable wall  161 , gussets  331 ,  332 ,  333  that help to guide the moveable wall  161 , and an adjustment knob  334  and an attached threaded shank  336  that extend into and through an attached nut  338 . The adjustment knob  334  is maintained in place within a slot  340  in the housing of the bin  150 , and the floor  163  is maintained in vertical position by two times  342 . Two springs  344  surround the posts  314  between the moveable wall  161  and the vertical panel  304 .  
         [0073]     In addition, the floor  163  includes a series of apertures  349  located to the side of the dispensing channel  154 . These apertures  349  can provide additional flow to this region of the bin  150 . The additional flow can encourage tablets that tumble to a position adjacent the dispensing channel  154  during agitation to rejoin the remaining tablets; otherwise, they may remain in this “dead” area, which can tend to clog entry into the dispensing channel  154 .  
         [0074]     To adjust the width of the dispensing channel  154  ( FIG. 22 ), the adjustment knob  334  is rotated about its axis. Rotation of the shank  336  within the nut  338  induces the floor  163  to slide horizontally between the housing  151  and the times  342 . In doing so, the posts  314  are free to slide through the apertures in the vertical panel  304 ; the moveable wall  161  is maintained in contact with the floor  163  by compression from the springs  344 . In the illustrated embodiment, the exact position of the moveable wall  161  can be monitored with markings  346  located on the rear portion of the floor  163 .  
         [0075]     To adjust the height of the ceiling  162  ( FIG. 21 ), the adjustment knob  320  is rotated. Interaction between the shank  322  and the nut  324  causes the ceiling unit  302  to slide within the recess  301 . The posts  314  slide within the slots  316  in the housing  151 , and the moveable wall  161  is driven upwardly or downwardly by the ceiling  162 . The front projection  318  of the moveable wall  161  remains in the slots  319 ,  330 . The exact position of the ceiling  162  can be monitored with markings  348  located on the side of the housing  151 .  
         [0076]     Notably, the configuration of the dispensing channel  154  described above can provide an essentially “gapless” channel for the tablets to travel in, which can improve performance of the system  40 . Also, the floor  163  and the stationary wall  160  of the dispensing channel  154  remain in place, which provides a constant location to which the container receiving tablets can be delivered.  
         [0077]     A further optional feature of the illustrated dispensing channel  154  is a splash guard  158  ( FIG. 28 ), which is located at the outlet of the dispensing channel  154 . The splash guard  158  can reduce or eliminate the risk that a tablet traveling to the container falls or bounces outside the container. In one embodiment, the splash guard  158  is formed of a spongy foam material (such as polyethylene foam); such a material enables the container to be compressed against the splash guard  158 , causing it to deform around the upper edge of the container and seal it so that tablets do not stray from the container. With a splash guard of this construction, the presentation of the container to the dispensing channel  154  by the dispensing carrier  70  can occur with a larger margin for error in positioning.  
         [0078]     Another feature of the tablet dispensing station  62  that may be included with the present invention is illustrated in  FIGS. 3 and 23 - 25 . As can be seen therein, a low pressure manifold  170  having a number of inlets  171  is mounted to the frame  44  and extends horizontally; the manifold  170 , which is fluidly connected to a low pressure source such as a vacuum motor (not shown), provides low level (i.e., about 2 psi) suction to the bin  150  to either (a) maintain a door  172  in a closed position when the particular bin  150  is not in use or (b) agitate tablets within the bin when the door  172  is opened by a solenoid  173  or other actuating unit within the bin  150 . Of course, individual blowers may be used for each bin in lieu of the manifold  170  with multiple inlets  171 . Also, a high pressure (i.e., about 30 psi) conduit  175  with a fitting  176  also extends horizontally from its mounting point on the frame  44 , with the fitting  176  projecting toward the bin  150 . The fitting  176  may be a check valve, so that high pressure air is not expelled if the bin  150  is not present. The high pressure conduit  175  is fluidly connected to a high pressure source (not shown). Further, a connector circuit board  177  is mounted horizontally below the manifold  170 ; the circuit board  177  or other electrical connector provides an electrical connection between the controller  42  and the bin-controlling circuit board  177   a  (or other electronic component) of the bin  150  for power and data signals from the controller  42 , such as those that control the opening and closing of the door  172 , the application of suction and/or positive pressure through the conduit  175 , and the counting sensor  154   a.  Thus, all three of these connections should be made for the bin  150  to operate.  
         [0079]     Despite the presence of the hopper door  180  through which the hopper  153  can be refilled, there are instances for which it would be desirable to remove the bin  150  from the frame  44  (for example, to adjust the size of the entry to the dispensing channel  154 ). When the bin  150  has been removed, reinstallation requires that connections be re-established between the bin  150  and the manifold  170 , the conduit  175 , and the connector circuit board  177 .  
         [0080]     The frame  44  illustrated herein includes prongs  183  ( FIG. 23 ) that facilitate re-establishment of the aforementioned connections. The prongs  183  are positioned below the manifold  170  and are configured for slidable movement with slots  184  on the housing  151  that receives the prongs  183 . The prongs  183  include recesses  183 a that receive pins  187  located on a pivoting member  189 . As the prongs  183  slide to completely fill the slots  184 , an opening  172   b  of the housing  151  aligns with an inlet  171  of the manifold  170 , the bin-controlling circuit board  177   a  located on the front edge of the hopper  153  comes into contact with the connector circuit board  177 , and a fitting  188  that extends from the front of the housing  151  below the bin-controlling circuit board  177   a  locks with the fitting  176  of the conduit  175 . As such, simply sliding the bin  150  back into place ( FIGS. 23 and 24 ) can re-establish all of these operative connections without additional steps. The bin  150  can be secured firmly into place by pivoting the member  189  so that the posts  187  fill the slots  183   a  ( FIGS. 24 and 25 ).  
         [0081]     Referring now to  FIG. 23A , the connector board  177  is mounted to the frame  44  and supports electronic circuitry which contains a “location identifier” unique to the physical location of the connector board  177  on the frame  44 . The connector board  177  provides its mating bin-controlling circuit board  177   a  with regulated and unregulated power, a physical connection to the data bus  177   b,  and the location identifier for the connector board  177 . The connector board  177  communicates power and data to the bin-controlling circuit board  177   a  via the bus  177   b  (which is a power and data bus).  
         [0082]     Still referring to  FIG. 23A , the bin-controlling circuit board  177   a  contains a “bin identifier” unique to that bin that can be read by the controller  42 . The bin-controlling circuit board  177   a  processes counting and dispensing functions such as triggering the solenoid  173 , triggering the air valves  190 , and processing signals from the sensor  154   a.  The bin-controlling circuit board  177   a  can receive dispense instructions and communicate its unique identifier and other information relative to its counting function, such as count status, empty condition, and the like. In some embodiments the bin-controlling circuit board  177   a  may also send or receive data such as inventory levels or sensor condition. Upon command from the controller  42  the bin controlling circuit board  177   a  can initiate and control the dispense and count process.  
         [0083]     With this configuration, the controller  42  can search for a unique bin identifier and associate it with a certain location identifier. The controller  42  may then direct the dispensing carrier  70  to carry the container to the appropriate position for dispensing. Thus, once a pharmaceutical has been associated with a particular bin  150  via its “bin identifier”, accurate dispensing of the pharmaceutical becomes independent of a priori knowledge of the pharmaceutical&#39;s physical location on the frame  44 . This gives the user the ability to quickly re-arrange the bin locations according to changing requirements such as alphabetization or utilization ranking.  
         [0084]     Referring now to  FIG. 23B , in other embodiments of the system  42 , each bin  150  may contain an additional machine readable identifier  150   a  which is more readily accessible to an operator wielding a reader  150   b  which is connected to the controller  42 . Using this reader  150   b,  the operator may select and read the bin identifier  150   a  to automatically associate various external data such as pharmaceutical identifiers, replenishment quantities, etc., to the bins&#39; information set. This identifier  150   a  may be placed on the inside of the replenishment door  180  so that the door  180  must be opened before the reader can access the identifier  150   a.    
         [0085]     To fill the container, the dispensing carrier  70 , directed by the controller  42 , moves the container to the exit port of the selected dispensing bin  150 . The controller  42  signals the solenoid  173  to open the door  172  (more specifically, the solenoid  173  retracts, and a plunger  173   a  moves toward the door  172 , striking a finger  172   a  located on the top portion of the door  172  and causing it to pivot open—see  FIG. 27 ). This opening of the door  172  draws low pressure air up through the hopper  153  from a screen  153   a  on the bottom of the hopper  153 , through another screen  153   b  on the top portion of the hopper  153 , and to the opening  172   b,  thereby agitating the tablets contained in the hopper  153  ( FIG. 27 ). Once agitation has commenced, the controller  42  signals a valve  190   a  connected with the forwardly-directed jets to open, which causes high pressure air to be drawn outwardly through the dispensing channel  154  ( FIG. 28 ). Tablets are oriented into a preferred orientation by the shape of the entry to the dispensing channel  154  and dispensed into the container through the dispensing channel  154 . The counting sensor  154   a  counts the tablets as they pass through a predetermined point in the dispensing channel  154 . Once dispensing is complete (i, a predetermined number of tablets has been dispensed), the controller  42  activates the valve  190   b  associated with the rearwardly-directed jet  56  and deactivates the dispensing bin  150 , the solenoid  173  deactivates, thereby closing the door  172  ( FIG. 29 ), and the dispensing carrier  70  moves the filled container to the closure dispensing station  64 .  
         [0086]     Referring now to  FIGS. 30-37 , the closure dispensing station  64  includes two closure dispensers  200  and two closure holders  202 , each of which is mounted to the intermediate arch  55  of the frame  44  between the container dispensing station  58  and the labeling station  60 . Typically, each closure dispenser  200  and closure holder  202  contains and manipulates a single size of closure. The closure dispensers  200  house a bulk supply of closures and dispense them, in a preferred orientation, one at a time to a respective closure holder  202 , where they are secured onto a filled container. One each of a closure dispenser  200  and a closure holder  202  are described in detail below; those skilled in this art will appreciate that any number of closure dispensers and closure holders may be employed with the present invention.  
         [0087]     The closure dispenser  200  ( FIGS. 30-34 ) includes an open-ended bin  204  that feeds a rotatable hopper  206 . The hopper  206  has an open top end to receive closures from the bin  204  and a circumferential groove  208  at its lower end that surrounds a central circular island  209 . The groove  208  has a depth that is approximately the diameter of a closure and a width that is approximately the width of the closure. A circumferential protrusion  210  juts radially inwardly from the wall  207  of the hopper  206  above the groove  208  and island  209 . The sizes and configurations of the groove  208 , island  209  and protrusion  210  are such that a closure (which is a flat, open-ended cylinder) can enter the groove  208  from above only when the closure is oriented so that the open end of the closure faces the island  209 . This occurs because the open end of the closure can receive a portion of the edge of the island  209 , thereby allowing the closure to be positioned slightly farther from the wall  207  (and, therefore, slide into the groove  208 ) than a closure oriented with the closed end facing the island  209 , which cannot pass between the island  209  and the protrusion  210  in this manner (compare  FIGS. 32 and 33 ).  
         [0088]     The floor  211  of the hopper  206  has an opening  213  through which one closure can pass. The floor  211  abuts a plate  214  ( FIG. 34 ) that also includes at least one opening  212  that has a length in a direction substantially tangent to the groove  208  that is sufficient to pass one closure. The hopper  206  is rotatably mounted on the plate  214 . A channel  218  is positioned below the opening  212  and leads to the closure holder  202 ; the channel  218  is sized such that the closure substantially maintains the orientation it takes upon exiting the opening  212 .  
         [0089]     Closures are dispensed by filling the bin with closures and rotating the hopper  206  relative to the plate  214 . As the hopper  206  rotates, each closure tumbles until it eventually reaches the desired orientation and slides into the groove  208  (tumbling of the closures is augmented by two agitating projections  209   a ). As the hopper  206  continues to rotate, the closure eventually reaches the opening  213 , at which point it passes through the opening  212  and falls into the channel  218 . The channel  218  conveys the closure in its desired orientation to the closure holder  202 .  
         [0090]     Those skilled in this art will appreciate that other techniques for separating and orienting closures may also be employed. For example, a conventional “pick-and-place” device may be used. Additional sensors and controllers may also be used.  
         [0091]     Referring now to  FIG. 35 , the closure holder  202  includes a vertical mounting post  222  upon which are mounted a container receiving stage  224  and a closure holding stage  226 . The container receiving stage  226  comprises a block  228  that is slidable relative to the mounting post  222  driven by a rack-and-pinion drive unit  227 . A platform  230  extends generally horizontally away from the block  228 . Two open-ended cups  232   a,    232   b  sized to receive filled containers are mounted on the upper surface of the platform  230 . A rotatable drive wheel  233  or other rotary drive unit is positioned between the cups  232   a,    232   b  that rotates the cups  232   a,    232   b  about their respective longitudinal axes; rotation of the drive wheel  233  is controlled by the controller  42 .  
         [0092]     Referring still to  FIG. 35 , the closure holding stage  226  has a ceiling  234  and three downwardly-extending walls  236  that form two closure securing compartments  238 . A fork  239  is mounted to the mounting post  222  and forms the rear wall of the securing compartments  238 ; the fork  239  includes openings that receive closures from the channels  218 . A pair of ledges  240   a,    240   b  extend into each compartment  238  from the opposing surfaces of the walls  236 . The ledges  240   a,    240   b  extend a sufficient distance from the walls  236  that a closure cannot pass downwardly between the ledges  240   a,    240   b,  but a container can pass upwardly between them. The ledges  240   a,    240   b,  walls  236  and ceiling  234  are also configured so that a closure can pass forwardly (i.e., away from the fork  239 ) to allow a combined container and closure to pass out of the compartments  238 .  
         [0093]     Returning to the operation of the system  40 , after the container is filled with tablets at the tablet dispensing station  62 , the dispensing carrier  70  grasps the filled container, conveys it to the closure dispensing station  64 , and places it in a selected cup  232   a,    232   b  as directed by the controller  42  ( FIG. 35 ). The block  228  slides upwardly relative to the mounting post  222 , thereby moving the platform  230  upwardly. The platform  230  ascends, and the upper end of the container contacts and intercepts the closure positioned in the compartment  238 . The container and closure continue to rise until the container compresses the closure against the ceiling  234  ( FIG. 36 ). The selected cup  232   a  then rotates, thereby rotating the container, as the ceiling  234  holds the closure in place, causing the container to rotate relative to the closure. This rotation secures the closure to the container. The platform  230  then lowers; the closed container descends until the closure contacts the ledges  240   a,    240   b,  with the closed container dangling therefrom ( FIG. 37 ). The dispensing carrier  70  then moves to the closed container, grasps it, and moves it to the offloading station  66 .  
         [0094]     Referring now to  FIG. 2 , the offloading station  66  includes a plurality of compartments  250  positioned between the intermediate and upper arches  55 ,  54 . These can be organized in any manner desired by the operator; for example, they may be organized by customer name, time of dispensing, contents of the container, or any other scheme. The dispensing carrier  70  conveys the closed container to the compartment directed by the controller  42  and releases it there. The dispensing carrier is then free to grasp another labeled container at the labeling station  60  and perform its operations again.  
         [0095]     The foregoing is illustrative of the present invention, and is not to be construed as limiting thereof. Although exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. As such, all such modifications are intended to be included within the scope of this invention. The scope of the invention is to be defined by the following claims.

Technology Classification (CPC): 6