Abstract:
A bucket carrier for carrying buckets ( 2 ) to store them in each storage shelf of a cart ( 4 ), the bucket carrier comprising a holding means ( 20 ) for holding buckets ( 2 ), and carrier means ( 28 ) for carrying the buckets ( 2 ) held by the holding means ( 20 ) to each storage shelf ( 49 ) of the cart ( 4 ). The arrangement is such that the holding means ( 20 ) and a transfer means ( 49 ) are drive-controlled so that the buckets ( 2 ) are stored in the storage shelves ( 49 ) obliquely from above. Thereby, the buckets ( 2 ) can be automatically stored in the cart ( 4 ).

Description:
BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The present invention relates to a bucket transfer apparatus. 
     2. Description of the Related Art 
     When transferring medications from a pharmacy department, medications for one patient are conventionally placed in a bucket and are automatically transferred to a nurse station using a transfer apparatus (see, for instance, Japanese Laid-Open Patent Publication No. 8-310625). However, since it is ineffective to individually transfer those buckets from the nurse station to the respective patient rooms, a plurality of buckets are stored in a cart whereupon they are collectively transferred. 
     However, it is extremely troublesome to store all of the many buckets on the cart. Moreover, due to employment of an arrangement that prevents the stored buckets from falling off during transfer on the cart, there is a drawback in that they are hard to store. Thus, it has long been desired to provide an arrangement in which buckets can be automatically stored on carts. 
     SUMMARY OF THE INVENTION 
     The present invention thus aims to provide a bucket transfer apparatus that is capable of automatically storing buckets on a cart. 
     As a means for solving the problem, the present invention provides a bucket transfer apparatus for transferring buckets and storing them in respective storage racks of a cart. The device includes a holding means for holding the buckets, and a transfer means for transferring the buckets held by the holding means to the respective storage racks of the cart. 
     The holding means and the transfer means are driven and controlled such that the buckets are stored from obliquely above with respect to the storage racks. 
     A conventional storage rack, arranged to prevent falling off of buckets during transfer, was provided with projections on both ends of guiding grooves of the racks so that it was hard to store the buckets from directions parallel to the racks. According to the arrangement of the present invention, since buckets are stored from obliquely above, it is possible to smoothly deliver the buckets to the racks. 
     It is preferable that the holding means includes opening/closing arms for closing while lifting to hold a bucket from both sides and opening while descending to release the bucket, and push-out portions for pushing the bucket held by the opening/closing arms out in a horizontal direction. 
     When pushing the bucket out by the push-out portions, a rear wall of the bucket, below a brim portion on its rear end side, is pushed, and when a front end of the bucket is located above a lower edge portion of the storage rack on an intrusion side, the opening/closing arms are opened while descending to move the bucket down while releasing the holding condition of the bucket. Thus, it is possible to smoothly store the bucket on a storage rack of the cart with the use of a simple arrangement. 
     It is further preferable that the device includes a turning means for turning the bucket, and reading means for reading an identification card attached to an outer side of the bucket. 
     The turning means is driven and controlled so as to allow the identification card to be read by the reading means, and the bucket is transferred to the cart by the transfer means so that the identification card is located on the same surface side. Thus, it is possible to reliably and easily read the identification card irrespective of the direction of the bucket. 
     It is preferable that the transfer means includes a bucket detecting means for detecting the presence/absence of a bucket in the storage rack. The transfer means is driven and controlled based on a detection signal of the bucket detecting means for transferring the bucket to an empty storage rack. 
     It is preferable that the cart includes fixing means for fixing the buckets stored in the storage rack, that the device includes a non-fixed condition detecting means for detecting a non-fixed condition by the fixing means, and that the bucket is transferred by the transfer means based on the detection signal of the non-fixed condition detecting means. 
     According to the present invention, since buckets can be stored from obliquely above with respect to the storage rack, it is possible to achieve the effect of performing storage operations automatically and smoothly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of the bucket transfer apparatus according to the present embodiment; 
         FIG. 2  is a plan view of  FIG. 1 ; 
         FIG. 3  is a left-hand side view of  FIG. 1 ; 
         FIG. 4A  is a side view showing a bucket on its way to being stored in a cart, and  FIG. 4B  is a front view of the bucket; 
         FIG. 5  is a front view of a holding member; 
         FIG. 6  is a partially enlarged perspective view of  FIG. 5 ; 
         FIG. 7  is a plan view showing an identification card; and 
         FIG. 8A  to  FIG. 8C  are side views showing operations of storing the bucket on the cart in sequential form. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     An embodiment of the present invention will be explained in accordance with the accompanying drawings. 
       FIGS. 1 to 3  show a bucket transfer apparatus  1  according to the present embodiment. This transfer apparatus  1  includes a direction-changing portion  3  for changing directions of buckets  2 , and a transfer portion  5  for transferring the buckets  2  to a cart  4 . 
     As shown in  FIG. 4A  and  FIG. 4B , the bucket  2  has a box-like shape with an open top, and a brim portion  6  is formed at an aperture edge thereof. Engaging concaves  7  are respectively formed on both side portions atop of the brim portion  6  by providing projections on two spots, respectively. An identification card  8  is attachable/detachable on an end surface of the bucket  2 . The identification card  8  may be a leuco-type or thermochromic-type of rewritable card capable of being rewritten upon heating to a specified temperature. The identification card  8  bears pieces of patient information as shown in  FIG. 7 . 
     The direction-changing portion  3  is connected to a medication supplying device  9  for supplying medications to the bucket  2 . In the medication supplying device  9 , medications prescribed to each patient in accordance with prescription information are sequentially stored in the buckets  2  and are transferred to the direction-changing portion  3 . 
     The direction-changing portion  3  includes a transfer belt  10  and a turn table  11  for changing the direction of the bucket  2 . As shown in  FIG. 3 , the transfer belt  10  is arranged such that belts  14  are respectively arranged around pulleys  13  provided at rotating axes  12  at a predetermined distance wherein one of the rotating axes  12  is rotatably driven by a motor  15 . As shown in  FIG. 2 , the turn table  11  is disposed between both belts  14  and is provided in a freely elevating and rotating manner. By lifting and turning the bucket  2  transferred by the transfer belt  10 , the identification card  8  of the bucket  2  is made to face in the same direction. A first bucket detecting sensor  16   a  and a second bucket detecting sensor  16   b  are provided proximate the turn table  11 . The first bucket detecting sensor  16   a  is used for detecting that a bucket  2  is approaching the turn table  11  and for reducing the transfer speed of the transfer belt  10 . 
     The second bucket detecting sensor  16   b  is used for detecting that the bucket  2  has been transferred to a turning position upward of the turn table  11  and for terminating transfer by the transfer belt  10 . A stopper  17  for forcibly terminating movement of the bucket  2  at the turning position is provided proximate the turn table  11  (downstream side of the transfer direction) in a freely elevating manner. 
     Card detecting sensors  18  for detecting an identification card  8  attached to the bucket  2  are provided laterally of the turn table  11 . In this embodiment, it is possible to attach the identification card  8  to a total of four spots, namely two spots on both end surfaces of the bucket  2 , respectively. Therefore, by providing the card detecting sensors  18  on two spots and by turning the turn table  11  by 180 degrees in case the bucket  2  cannot be detected, the device is arranged such that the identification card  8  can be detected regardless of the location thereof. 
     A plurality of transfer rollers  100  are provided on a downstream side of the stopper  17  so that the bucket  2  can be transferred further downstream from the turning position. A stopper  101  is provided in a freely elevating manner on the downstream side of the turning position so that the movement of the bucket  2  can be forcibly terminated at a transfer preparation position. A rewrite device  19  is provided laterally of the stopper  101  so that pieces of information written on the identification card  8  can be rewritten in accordance with pieces of information written on prescriptions in a condition in which the bucket  2  is transferred to the transfer preparation position (in this embodiment, patient information are rewritten). 
     The transfer portion  5  is provided with a holding member  20  provided so as to be freely movable vertically and laterally within a transfer unit. A magnet sensor  22  for positioning and detecting the cart  4  (which will be discussed in detail below) and a lever detecting sensor  23  for detecting a rotating position of a lever  57  provided at the cart  4  are provided on a front surface side of a frame body  21  forming the transfer unit. 
     The transfer unit is provided, on both sides of its rear surface, with guiding axes  24  extending in a vertical direction, belts  25 , elevating rails  26 , and guiding guides  27  in this order from the rear surface side. Counter weights  24   a  are provided along the guiding axes  24  in a freely elevating manner, and elevating members  28  are provided along the elevating rails  26  in a freely elevating manner. The belts  25  are connected to the guiding axes  24  and the elevating members  28  and are driven through a motor for elevation (not shown) for elevating the elevating members  28 . Cable chains  29  are guided along the guiding guides  28  for protecting electric wires. Supporting arms  31  for performing reciprocating movements in horizontal directions upon being driven by a motor for horizontal movement  30  are provided at the elevating members  28 . The holding members  20  are provided at tip ends of the supporting arms  31 . 
     The holding members  20  are arranged such that holding pieces  33  are provided at lower end portions of a pair of opening/closing arms  32  so that the bucket  2  can be held from both sides upon opening and closing of these pieces. As shown in  FIGS. 5 and 6 , the opening/closing arms  32  perform elevating and opening/closing movements upon guiding both sides thereof through guiding plates  34 . More particularly, guiding rollers  35  are provided on both side portions of the opening/closing arms  32  arranged at a specified distance. The guiding plates  34  are provided with guiding grooves  36  on which the guiding rollers  35  rotate. Each guiding groove  36  includes a vertical portion  37   a  on an upper side and a sloped portion  37   b  on a lower side. When both guide rollers  35  are located in the vertical portions  37   a , they are at a holding position in which the holding pieces  33  are closest with respect to each other. And, as the lower guide rollers  35  move closer to the sloped portions  37   b , the holding pieces  33  descend and gradually separate from each other. The opening/closing arms  32  are connected at their upper end portions to a supporting table  38  in a freely rotating manner. The supporting table  38  is provided in a freely elevating manner along axis portions  39  erected at tip ends of the supporting arms  31  at a predetermined distance. A rack  40  is formed on the supporting table  38  and a pinion  42 , which is fixed to a rotating axis of a motor  41  for opening/closing movements, is in mesh therewith. Accordingly, when the motor  41  for opening/closing movements is driven, the supporting table  38  is elevated through the pinion  42  and the rack  40 , and with the guiding rollers  35  rolling along the guide grooves  36 , the opening/closing arms perform opening/closing movements while performing elevating movements. 
     As shown in  FIG. 2 , push-out portion supporting arms  43   a  are provided downward of the supporting arms  31  and push-out members  43  for performing reciprocating movements in a longitudinal direction are provided downward of the push-out portion supporting arms  43   a . The push-out members  43  are coupled to belts  45  wound around pulleys  44  provided on both ends of the push-out portion supporting arms  43   a  and perform reciprocating movements in a longitudinal direction upon rotating one of the pulleys  44  through a motor  46 . Rotation of the pulleys  44  is detected by an encoder  47 , and moving positions of the push-out members  43  are controlled based on results of the detection thereof. The push-out members  43  move forward up to proximate of end surfaces of the bucket  2  held by the holding pieces  33  of the opening/closing arms  32 , and are capable of supporting the brim portion  6  of the bucket  2  at their upper edge portions. The push-out members  43  push the bucket  2  out to the cart  4  side. As shown in  FIG. 5 , the push-out supporting arms  43   a  are provided with bucket presence/absence detecting sensors  48  at their tip ends so that presence/absence of buckets  2  stored in the cart  4  can be detected by detecting an identification card  8  attached to the buckets  2 . 
     As shown in  FIG. 3 , the cart  4  is a frame-like body including a plurality of storage racks  49  arranged vertically and horizontally, wherein a lower end portion of the cart is provided with casters  50  at four corners thereof and the cart is freely movable upon gripping a grip  51  provided at an upper portion thereof. As shown in  FIG. 4A , the storage racks  49  are arranged such they can support the brim portions  6  of the buckets  2  through guiding grooves  52  formed on both sides thereof. 
     Projections  53  are formed on both ends of lower edge portions  52   a  forming the guiding grooves  52 . By guiding both ends of a brim portion  6  of a bucket  2  being transferred into the storage rack  49  through the projections  53 , it is possible to stabilize the mounted condition of the bucket  2  in the storage rack  49 . Relief concaves  54  are formed inside of the respective projections  53 . 
     Projections  55  are respectively formed on both ends of upper edge portions  52   b  forming the guide grooves  52  at positions corresponding to the relief concaves  54  of the lower edge portions. It is possible to stabilize the holding condition of the bucket  2  in the storage rack  49  through the projections  55  and the projections  53 . Pressing portions  56  capable of performing elevating movements are provided centrally of the upper edge portions  52   b . The pressing portions  56  of the respective storage racks  49  are uniformly lifted to an unlocked position through a rod  58  upon rotating the lever  57  as shown in  FIG. 3 , and then descend to a locked position. At the locked position, the pressing portions engage engaging concave portions  7  formed on top central portions of the brim portions  6  of the buckets  2  mounted on the respective storage racks  49  for holding the buckets  2  so as to be unmovable. The rotated position of the lever  57 , that is, the locked position facing vertically downward is detected by the lever detecting sensor  23  provided at the transfer portion  5 , and the transfer portion  5  is drivable only when the lever is in the unlocked position. 
     Next, operations of the bucket transfer apparatus  1  of the above structure will be explained. 
     The cart  4  is moved to a position adjacent the transfer portion  5 . The cart  4  is positioned by the magnet sensor  22  provided at the transfer portion  5 . When the cart  4  is detected by the magnet sensor  22  and when it is detected by the lever detecting sensor  23  that the lever  57  is at the unlocked position, supply of medications to the buckets  2  is started per units of patients based on prescription information sent to the medication supplying device  9 . Buckets  2  supplied with medications for one patient are sequentially transferred from the medication supplying device  9  to the direction-changing portion  3 . 
     In the direction-changing portion  3 , the stopper  17  is lifted and the transfer belt  10  is driven. The transfer belt  10  is then reduced in speed based on a detection signal of the first bucket detecting sensor  16   a  and, upon terminating operation of the transfer belt  10  based on a detection signal of the second bucket detecting sensor  16   b , the bucket  2  is positioned smoothly on the turn table  11 . Next, upon lifting the turn table  11  and holding the bucket  2  up, it is turned by 90 degrees for detecting an identification card  8  attached to the bucket  2  by means of the card detecting sensors  18 . When no identification card  8  can be detected, the turn table  11  is turned by 180 degrees. In this manner, when the bucket  2  is turned such that the identification card  8  is positioned at the side of the card detecting sensors  18 , the turn table  11  and the stopper  17  descend in order to restart driving of the transfer belt  10  and driving of the transfer rollers  100  is started. Movement of the bucket  2  is again terminated by the stopper  101 , and upon rewriting contents of the identification card  8  by the rewrite device  19  based on pieces of prescription information, the bucket  2  is further transferred to the transfer portion  5 . 
     In the transfer portion  5 , the elevating members  28  descend and the supporting arms  31  are moved towards the direction-changing portion  3  so as to move the holding members  20  towards the transferred bucket  2 . At this time, the motor for elevating movements is driven to release the opening/closing arms  32  and separate the holding pieces  33 . When the holding members  20  move to a position at which they are capable of holding the bucket  2 , the motor for elevating movements is driven such that the bucket  2  is held from both sides by means of the holding pieces  33 , and brim portions  6  on both sides are supported on the holding pieces  33 . At this time, the elevating members  28  are lifted and the supporting arms  31  are moved horizontally to move the bucket  2  to a storage rack  49  located on one end side of a topmost stage of the cart  4 . At this time, the bucket presence/absence detecting sensor  48  detects whether a bucket  2  is stored in this storage rack  49  or not. When there is not, the bucket  2  is stored in this storage rack  49 , and when there is, the bucket  2  is stored in an adjoining storage rack  49 . The same operations are repeated until storage on all storage racks  49  of the topmost stage is completed, and storage on lower storage racks  49  is sequentially performed. In this manner, since buckets  2  are stored upon detecting through the bucket presence/absence detecting sensor  48  whether buckets  2  are stored in the respective storage racks  49  of the cart  4  or not, it is possible to automatically select an empty storage rack  49  and perform storage. Accordingly, even if a stored bucket  2  is being delivered to a patient in advance for emergency purposes or the like during storage operations of the buckets  3  into the cart  4 , the next bucket  2  can be automatically stored in the empty space so that all storage racks  49  can be utilized without loss of storage space. 
     When performing storage of the buckets  2  on the storage racks  49 , the supporting arms  31  are moved such that the brim portion  6  of the buckets  2  becomes higher than the lower edge portions  52   a  of the guide grooves  52  of the storage racks  49  as shown in  FIG. 8A . Then, as shown in  FIG. 8B , the push-out members  43  are moved forward for pressing a rear wall of the bucket  2  to move the bucket  2  towards the cart. With this arrangement, the brim portion  6  on the front end side of the bucket  2  enters the storage rack  49  and the front end portion is positioned upon moving across the projections  53  on the intrusion side. At this time, the motor for opening/closing movements  41  is driven to release the opening/closing arms  32 . In the releasing operations of the opening/closing arm  32  as shown in  FIG. 6 , the guide rollers  35  on the lower side are slid from the vertical portions  37   a  of the guiding grooves  36  towards the sloped portions  37   b  whereby the holding pieces  33  descend while gradually separating. Accordingly, when the bucket  2  is released from the condition in which it is held by the holding pieces  33  as shown in  FIG. 8C , the front ends of the push-out members  43  engage the brim portion  6  at the rear end side of the bucket  2  such that the brim portion  6  on the front end side of the bucket  2  is mounted to the lower edge portions  52   a  of the guiding grooves  52 , and the bucket  2  itself inclines so that its front end is positioned below the level of its rear end. Therefore, when the push-out members  43  are further moved forward, the bucket  2  will be smoothly stored within the storage rack  49  without interfering with the projections  53  as shown in  FIG. 4A . Further, since relief concaves  54  are formed at positions opposing the projections  55 , the bucket  2  will not interfere with the projections  55 , either. When the push-out members  43  are retracted upon completion of storage, it is possible to position the bucket  2  within the storage rack  49  in a stable condition by means of the projections  53 ,  55 .