Source: http://www.google.com/patents/US8146331?ie=ISO-8859-1
Timestamp: 2014-07-10 16:32:10
Document Index: 266219671

Matched Legal Cases: ['art 1', 'art 2', 'art 3', 'art 4', 'art 5', 'art 6']

Patent US8146331 - Automated packaging, inspection, verification, and counting apparatus - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign in<nobr>Advanced Patent Search</nobr>PatentsThe present invention is an automated packaging apparatus utilizing a rotating assembly of elongated slats containing cavities to receive discrete pharmaceutical, vitamin, or food products. Quantities of discrete products such as tablets, capsules, or gels are deposited into the hopper of the apparatus....http://www.google.com/patents/US8146331?utm_source=gb-gplus-sharePatent US8146331 - Automated packaging, inspection, verification, and counting apparatusAdvanced Patent SearchPublication numberUS8146331 B2Publication typeGrantApplication numberUS 12/354,561Publication dateApr 3, 2012Filing dateJan 15, 2009Priority dateJan 15, 2009Also published asUS20100175352Publication number12354561, 354561, US 8146331 B2, US 8146331B2, US-B2-8146331, US8146331 B2, US8146331B2InventorsSabrie SolomanOriginal AssigneeSabrie SolomanExport CitationBiBTeX, EndNote, RefManPatent Citations (30), Referenced by (3), Classifications (10) External Links: USPTO, USPTO Assignment, EspacenetAutomated packaging, inspection, verification, and counting apparatusUS 8146331 B2Abstract The present invention is an automated packaging apparatus utilizing a rotating assembly of elongated slats containing cavities to receive discrete pharmaceutical, vitamin, or food products. Quantities of discrete products such as tablets, capsules, or gels are deposited into the hopper of the apparatus. The apparatus then dispenses the discrete products into containers moving on a conveyor system such that each container receives a predetermined quality and quantity of pharmaceutical, vitamin, or food products. While operating at high speed, the apparatus inspects, counts, identifies and analyzes each product deposited into the containers and maintains electronic records describing the status of each product. In the event any errors occur the apparatus produces various alerts to inform the operator. The presence of foreign products or objects may cause the apparatus to instantly stop the entire system including peripheral equipment. A series of Good Manufacturing Practice protocols can then be enforced as per FDA requirements.
That which is claimed is: 1. An automated packaging apparatus comprising:
a reservoir configured to receive discrete product units;
a plurality of rotating linear elongated slats attached to said drive system, each slat having a proximal end and a distal end;
a plurality of cavities arranged along the longitudinal axis of each said slat, wherein each cavity is bifurcated by a channel passing through the cavity;
rake blade means for raking said channels in the bifurcated cavities and expelling all objects;
a divider assembly;
a dispenser assembly comprised of a plurality of manifolds connected to chutes configured to dispense predetermined quantities of discrete product units into containers moving proximate to the packaging apparatus.
2. The automated packaging apparatus of claim 1 further comprising a plurality of level sensors for detecting the presence of product units in the hopper, a plurality of vibrating motors activated by the level sensors, and circuits which adjust the motor vibrations, whereby product units may be distributed within the hopper.
3. The automated packaging apparatus of claim 1 wherein the aperture of each said cavity is curved to facilitate the receiving and dispensing of discrete product units.
4. The automated packaging apparatus of claim 1 wherein said control system further includes a PLC (programmable logic controller) and associated logic circuits and relays to control the various components of the apparatus including said drive system.
5. The automated packaging apparatus of claim 1 wherein said divider assembly comprises:
a plurality of adjacent contoured divider plates, each divider plate configured to convey a predetermined quantity of discrete products;
a plurality of diverters proximate to the divider plates configured to convey groups of discrete products to specific tiers in said dispenser assembly;
a diverter control assembly;
whereby discrete product units are conveyed from the bifurcated cavities into said dispenser assembly.
6. The automated packaging apparatus of claim 1 wherein said dispenser assembly comprises:
a plurality of manifolds, wherein each manifold is comprised of a plurality of adjacent funnel shaped cups arranged in a linear tier;
a plurality of linear chute tiers, wherein each chute tier is comprised of a plurality of adjacent chutes, each chute connected to the outlet of a said funnel shaped cup;
whereby discrete product units are conveyed into containers moving proximate to the outlets of the chute tiers.
7. The automated packaging apparatus of claim 1 wherein each said slat is comprised of FDA approved material.
8. The automated packaging apparatus of claim 1 further including a timing system comprising:
a plurality of timing screws;
a plurality of timing screw drives;
a plurality of servo-motors connected to said timing screws;
a plurality of electronic encoders connected to said timing screws;
a plurality of synchronizing wheels;
a plurality of synchronizing pins;
whereby products units are dispensed when containers are correctly positioned proximate to said dispenser assembly.
9. The automated packaging apparatus of claim 1 further including an alerting system which produces visual and audio alarms indicating various conditions of the apparatus including powering up, normal operation, fault conditions, and detection of flawed or foreign products.
10. The automated packaging apparatus of claim 1, further including an analysis system comprised of a high performance computer system and associated arithmetic circuits, data acquisition circuits, a storage system configured for storing and retrieving data, a computer operating system, and a means for recording and analyzing data.
11. The automated packaging apparatus of claim 10, further including a vision inspection system comprising:
a plurality of cameras mounted in proximity to said slats, wherein each camera is configured to capture chromatic imaging data from a specific group of said cavities;
a plurality of servo-motors and encoders configured to precisely control the position of each camera so as to synchronize the capture of imaging data;
means for computing and electronically recording in real time at high production speeds the visual characteristics of each product unit being dispensed by the packaging apparatus.
12. The automated packaging apparatus of claim 11, further comprising:
means for computing and electronically recording at high production speeds the weight, volume, dimensions, color, and physical integrity of each product unit within the packaging apparatus;
means for computing and electronically recording at high production speeds visual product unit flaws including incorrect colors and incorrect dimensions;
means for computing and electronically recording at high production speeds visual product unit flaws including foreign, dirty, deformed, or physically damaged product units;
means for computing and electronically recording the quantity of each said product unit being conveyed in the packaging apparatus;
means for electronically correlating and recording at high production speeds each product unit and its visual data;
means for computing and electronically recording at high production speeds the quantity of product units dispensed to each said container;
means for producing appropriate alerts and interrupting the packaging apparatus when the incorrect quantity of product units has been dispensed to any said container;
means for producing appropriate alerts and interrupting the packaging apparatus when visually flawed or foreign product units are detected;
means for creating a secure electronic audit trail of the visual product unit data.
13. The automated packaging apparatus of claim 11 wherein said cameras are installed within the packaging apparatus.
14. The automated packaging apparatus of claim 11 wherein said cameras are installed external to the packaging apparatus.
15. The automated packaging apparatus of claim 10, further including a spectroscopy inspection system comprising:
means for performing a high speed, real time analysis of the exact chemical composition of each product unit within the packaging apparatus.
16. The automated packaging apparatus of claim 15, wherein the spectroscopy inspection system comprises a high speed, production type spectroscopy system containing approximately eighty near-infrared fiber optic probes.
17. The automated packaging apparatus of claim 10, further including:
a plurality of fiber optic probes configured to capture reflected infrared spectroscopic data from said product units;
means to transmit collimated infrared beams through said fiber optic probes onto said product units;
a spectrophotometer configured to receive data from said fiber optic probes;
means to transmit spectrophotometer data to said analysis system;
means for computing and electronically recording in real time at high production speeds each product unit's dissolution measurement, hardness, and disintegration;
means for computing and electronically recording in real time at high production speeds the exact amount of active ingredients by weight of each product unit;
means for creating a secure electronic audit trail of the spectroscopic product unit data;
means for producing appropriate alerts and interrupting the packaging apparatus when chemically flawed product units are detected.
18. The automated packaging apparatus of claim 1 further including:
a bar code reader configured to scan bar code data on said containers;
means for correlating and recording visual and chemical product unit data with the product containers;
whereby product unit safety will thereby be assured.
19. An automated packaging apparatus comprising:
a timing system;
a plurality of diverters proximate to the divider plates;
a plurality of linear chute tiers, wherein each chute tier is comprised of a plurality of adjacent chutes, wherein each chute is connected to the outlet of a said funnel shaped cup;
20. An automated packaging apparatus comprising:
dispenser means for conveying discrete products into containers moving proximate to the outlets of the dispenser means;
divider means for conveying groups of discrete products to said dispenser means. Description
CROSS-REFERENCE TO RELATED APPLICATIONS (Not Applicable.)
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT (Not Applicable.)
FIELD OF THE INVENTION This invention relates to packaging machines, and more particularly to automated packaging machines utilized for inspecting, counting, and verification of the physical and chemical composition of discrete pharmaceutical, vitamin, or food products such as tablets or capsules, and packaging them in containers.
DISCUSSION OF RELATED ART Pharmaceutical industries require automated packaging apparatus to count, inspect and package predetermined quantities of discrete dosage items such as capsules and tablets. These products must be manufactured, inspected, counted, and their active ingredients measured by weight. The products must be packaged in containers in accordance with strict Federal regulations, including exactly meeting the product count and information labeled on the containers, and insuring the correct chemical composition of the products. Several prior art devices are known which provide automated packaging of discrete pharmaceutical products. U.S. Pat. No. 6,799,413 to Aylward discloses an automated packaging apparatus including a plurality of independently rotatable slats containing tablet, capsule, or gel apertures. Open product containers move along a conveyor adjacent to the slats so that tablets are dispensed into the containers. A delivery sensor and controller are used to determine when a corresponding container is filled.
U.S. Pat. No. 4,674,259 to Hills provides a container filling machine including a plurality of elongated slats with cavities which dispense tablets or capsules into a set of chutes. A reciprocating mechanism drives the chutes to dispense tablets or capsules between the first and second rows of containers positioned at the filling station. To insure an accurate count of products in each container, an operator may be situated adjacent to the slats who must insure that each container is correctly filled. This method has several drawbacks including labor costs, the possibility of human error, and possible sterility problems.
SUMMARY OF THE INVENTION The present invention is directed to an automated inspection, chemical measurement and verification, counting and packaging apparatus for dispensing discrete pharmaceutical, vitamin, or food products into various types of empty containers moving on a conveyor belt, including but not limited to bottles, jars, boxes, and the like. These discrete products may comprise but are not limited to tablets, capsules, caplets, gels, vitamins, and the like.
The sequence of motions of the various components of the apparatus are controlled by a PLC (programmable logic controller). A bar code reader is configured to scan the affixed bar code on each container, so that the data recorded by the analysis system is correlated with each container, thereby insuring the safety of consumers utilizing said products.
DESCRIPTION OF THE DRAWINGS FIG. 1 is a front perspective view of the invention, illustrating an automated packaging apparatus;
FIG. 13.1 is Part 1 of 6 Parts of a Collective Flow-Chart of the Present Invention Describing Sequential Steps to Start PLC/PC 90, 800 as well as Starting all System Driving Components and Inspection Systems Including the Infrared Spectroscopy Analytical System 600;
FIG. 13.2 is Part 2 of 6 Parts of a Collective Flow-Chart of the Present Invention Describing the Initialization Sequence of the System Driving Components, and Selecting Specific Product for Packaging, Counting, Verification, Inspection, and Analysis, as well as a Sequence for Initializing the Main Motor 11 for a Jog Mode Function;
FIG. 13. 3 is Part 3 of 6 Parts of a Collective Flow-Chart of the Present Invention Stating Sequential Steps to Energize the Camera Tilt Motor 210 until the Activation Steps to Fill Hopper 20;
FIG. 13.4 is Part 4 of 6 Parts of a Collective Flow-Chart of the Present Invention Stating Sequential Steps of Filled Exiting Bottle 382 to Steps Ensuring Vision System 200 Verifies if Main Machine Motor 11 Must Stop as a Consequence of the Presence of a Foreign Product Representing a Fatal-Flaw, or Machine May Continue if the Flaw is Representing a Process-Flaw, which will be Rejected at a Later Instant;
FIG. 13.5 is Part 5 of 6 Parts of a Collective Flow-Chart of the Present Invention Stating Sequential Steps of Stopping the Machine to Conduct an FDA Audit/Report in Case of Detection of a Foreign Product Representing a Fatal-Flaw Product;
FIG. 13.6 is Part 6 of 6 Parts of a Collective Flow-Chart of the Present Invention Stating Sequential Steps of Removing Unwanted Foreign Object 42 to Steps of Restarting Machine Motor 11 Again.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The present invention will now be described more fully with reference to the accompanying figures. Although the accompanying figures show preferred embodiments of the invention, the invention may be embodied in many different forms and should not be construed as limited to the embodiments described herein.
As shown in FIGS. 1, 1.1, 1.2, and 1.3, the automated packaging apparatus 10 includes the main hopper 20, a plurality of elongated slats 30, the bottom cabinet 70, the vibrating motors 50, 52, 53, 54, the camera tilt motor 210, the Encoder 220, and the drive chain 100.
Turning to FIGS. 4 and 4.1 we are shown a detailed view of a linear elongated slat 30. Each slat 30 contains a plurality of cylindrical bifurcated cavities 42, each cavity divided by a gap 48. Each cavity contains apertures 40 in the shape of curved channels within the cavities 42 to receive and dispense pharmaceutical, vitamin, or food products. Each slat 30 is reinforced by a slat reinforcement 44 containing a tee shaped alignment 46 on its bottom which enters a grooved wheel 45 to stabilize the slat 30 at appropriate moments while the slat assembly is being rotated by the drive system. The ends of each slat 30 are constructed with pin holes 21, 23 which precisely fit the pins 25,27 located at each attached chain link 102, 104.
In FIGS. 9 and 9.1 are illustrated the real time spectroscopy system 600, which measures and inspects the chemical composition of the pharmaceutical, vitamin, or food products before they are dispensed into their containers. The real time spectroscopy system 600 includes a bundle of fiber optics probes 601 properly situated to focus and transmit infrared light waves on the passing tablets, capsules, gels, and organic-base compounds. The fiber optic probes 102 then receive the reflected infrared light waves from the same. The fiber optic probes 601 and 602 are placed at an optimum distance from the passing products. The optimum distance is automatically determined by the spectroscopy system allowing the exact optical distance to be maintained regardless of the shape and configuration of the passing products. The probe 602 which is receiving reflected infrared energies is directly linked to the spectrophotometer 600 to obtain the corresponding spectrum of each product passing under the combined sending and receiving fiber optic probes 601 and 602. A succession of collimated beams throughout the middle and near infrared spectrum are transmitted through the fiber optic probes 602 located above each product in the slat 30 cavity 42. The collimated beams are impinged against a sample or samples and the diffused component of the reflected light is measured throughout the spectrum. This diffuse component is analyzed by several algorithms including neural network methodologies to determine such characteristics as the contents and the active ingredients of the passing product.
During operation of the apparatus the slats 30 are rotating continuously, and at specific moments the slat cavities 42 are turned almost upside down (FIG. 4.1). The discrete products previously deposited inside the slat cavities 42 then fall into a divider assembly 110. In FIGS. 4, 6, and 6.1 are shown the divider assembly 110 containing a predetermined number of divider plates 112 comprised of contoured partitions 113 shaped to accommodate the movements of the slats 30. The contoured partitions 113 are configured to allow certain slat peak areas 49 to rotate very close to the edges of the contoured partitions 113, thereby trapping a certain number of cavities and enabling the corresponding products to fall from their cylindrical contoured channels 40 of slat 30 into the divider assembly 110. Within the divider assembly 110 is a divider dispensing compartment 118 and a diverter assembly 120 containing diverter controls 121. A set of diverters 120 are configured directly at the bottom of the divider assembly 110. The diverters 120 are activated at the correct instants to cause the discrete products to be conveyed to either set of front cups 130 or set of rear cups 132 in the dispenser assembly (FIG. 7). The containers themselves are arranged in a plurality of tiers beneath the manifold 140,142 in order to receive the products being deposited into them through a plurality of chute tiers 150, 152.
Turning to FIG. 11.1, 4, and 4.1, the bottle transporting and timing system includes a timing screw 252, a timing screw drive 253, and a plurality of synchronizing wheels 32, 34, 45, synchronized pins 25, 27 corresponding with slat positioning holes 21, 23 which insure that the packaging apparatus dispenses the pharmaceutical, vitamin, or food products into the containers when the containers are correctly positioned to receive the pharmaceutical, vitamin, or food products. The timing screw servo motors 253, 255 automatically activate timing screws 252, 254 at the correct moment to allow a set of filled containers to depart to the accept-reject station. The same timing screw 252, 254 then cause a fresh set of empty containers to be conveyed beneath the dispensing chutes 150, 152. The timing screws 252, 254 then stop while this new set of containers are filled with pharmaceutical, vitamin, or food products
A bar code reader 300 is configured to scan the affixed bar code on each container, so that the data generated by the vision inspection system 200 and the spectroscopy system 600 are recorded by the workstation analysis system 90 and are correlated with each container, including correlating the product data and date and time stamps of the pharmaceutical, vitamin, or food products, and thereby insuring the safety of consumers utilizing said products (FIG. 11.2).
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