AN APPARATUS AND METHOD FOR AUTOMATED SORTING AND ENVELOPING OF HOMOGENEOUS AND/OR HETEROGENEOUS SUBSTANCES
20200165022 ยท 2020-05-28
Inventors
Cpc classification
B65B57/10
PERFORMING OPERATIONS; TRANSPORTING
B65B35/10
PERFORMING OPERATIONS; TRANSPORTING
B65B61/025
PERFORMING OPERATIONS; TRANSPORTING
B07C5/34
PERFORMING OPERATIONS; TRANSPORTING
B07C5/02
PERFORMING OPERATIONS; TRANSPORTING
B07C5/36
PERFORMING OPERATIONS; TRANSPORTING
B07C5/3412
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65B57/10
PERFORMING OPERATIONS; TRANSPORTING
B65B35/10
PERFORMING OPERATIONS; TRANSPORTING
B65B61/02
PERFORMING OPERATIONS; TRANSPORTING
B07C5/34
PERFORMING OPERATIONS; TRANSPORTING
B07C5/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention relates to safer and more effective, comprehensive and economical apparatus and method that enables a fully-automated process for cutting, sorting and enveloping of combinations of individual units of homogeneous and/or heterogenous substances, including pharmaceutical products, which are retained in and/or without manufacturer's packaging, in exact customised quantities and combinations. There are also additional measures for ensuring appropriate quality controls at each step of the method. The invention ensures that the safety, efficacy and pharmacological properties of each medicine which are preserved at the time of consumption.
Claims
1. An apparatus for automated sorting and enveloping of homogeneous and/or heterogeneous substances which comprises of: a tracking unit for tracking homogeneous and/or heterogeneous substances including medicine/drug strips and information on such substance; a cutting unit to cut homogeneous and/or heterogeneous substances including medicine/drug strips; a Cartridge with slots for loading of individual units of homogeneous and/or heterogeneous substances including medicine/drug; a loading bay to load the Cartridges which contain the individual units of homogeneous and/or heterogeneous substances including medicine/drug; a motor hub for calibrating Cartridge slots for sorting of the individual units of homogeneous and/or heterogeneous substances including medicine/drug; a conveyor belt to carry the individual units of homogeneous and/or heterogeneous substances including medicine/drug into a pouch forming chute; a printing unit for labeling of film which is used for forming a pouch; a horizontal and vertical heat-sealers to seal the pouches for securing the enveloped individual units resulting in four side sealed pouches; a dispensing unit for dispensing of the sealed and labeled pouches; a filling unit for filling dispensed pouches into Carefills; and sensors that track radio frequency based tags, optical machine formats/codes, and/or individual unit movement using micro-stepper motors
2. An apparatus for automated sorting and enveloping as claimed in claim 1, wherein the tracking unit includes cameras and optical machine format readers.
3. An apparatus for automated sorting and enveloping as claimed in claim 1, wherein the cutting unit includes laser and HMI.
4. An apparatus for automated sorting and enveloping as claimed in claim 1, wherein the Cartridge contains multiple slots, a motor hub, motor arm and an outer cover with radio frequency based tag.
5. An apparatus for automated sorting and enveloping as claimed in claim 1, wherein installed sensors confirm loading individual units into Cartridge slots; confirm loading of correct Cartridges and quantities on loading bay confirm dispensing individual units from Cartridge slots onto the conveyor belt; confirm dispensing Pouch load of individual units into labeled pouch;
6. A method for automated sorting and enveloping of homogeneous and/or heterogeneous substances which comprises of: tracking of medicine strips; cutting of medicine strips into individual units and retaining the manufacturers' packaging and simultaneously scanning and obtaining images of the individual units; loading of the individual units into single slots of cartridges, tagged with an unique identification, while tracking the exact slot location of such individual units; confirming the loading of the individual units into single slots of cartridges by way of a sensor; loading of the cartridges into a loading bay which is loaded with the exact number of cartridges required for that specific order along with the exact type of cartridge; confirming loading of the correct cartridges and exact number of cartridges, required for that specific order, by way of a radio frequency or optical machine format readers; sorting of individual units, dispensed from the relevant cartridges to make pouch loads exactly in accordance to prescribed dosages; confirming dispensing of the individual units from each cartridge by way of a sensor; enveloping and labelling of the pouch load into a labelled pouch meant for dispensing exact quantities and combinations of medicines in a prescribed dosage over a specified period of time in chronological order of consumption; confirming the loading pouch load into the labelled pouch by way of a sensor; dispensing the pouches with exact quantities and combinations of medication, without removing the manufacturer's packaging, to the patient for consumption in chronological order over a specified period of time; and filling the pouches of one order into Carefills, which are then labelled with information about patient/consumer and complete Order.
7. The fully automated method as claimed in claim 6, wherein tracking of strips of medicines is performed by capture of images of the medicine strip and collection of manufacturer's information including name, batch number, expiry date as present on the medicine strip along with shape, size and optical machine readable code/format on the medicine strip.
8. The fully automated method as claimed in claim 6, wherein tagging of cartridge with unique identification is performed by programming in-built Radio frequency based tag or optical machine readable formats on each cartridge.
9. The fully automated method as claimed in claim 6, wherein the pouch that contains exact quantities and combinations of medicines in a prescribed dosage can be labelled in several languages including Braille.
10. The fully automated method as claimed in claim 6, wherein installed sensors confirm loading individual units into Cartridge slots; confirm loading of correct Cartridges and quantities on loading bay confirm dispensing individual units from Cartridge slots onto the conveyor belt; confirm dispensing Pouch load of individual units into labeled pouch;
Description
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0031] The following drawings are illustrative of particular embodiments for enabling system and method of the present invention and are not intended to limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description.
[0032]
[0033]
[0034]
[0035]
[0036]
[0037]
[0038]
[0039] Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure.
[0040] Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0041] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of skilled in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[0042] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
[0043] It is to be understood that the singular forms a, an, and the include plural referents unless the context clearly dictates otherwise.
[0044] Few terms used and referred in the present inventions are as follows:
[0045] Flat-tab refers to a small piece of cardboard or other material that represents one unit of non-pouchable medicine prescribed for consumption at one time. A flat-tab is enveloped into a pouch and serves as a reminder to the consumer for taking the corresponding non-pouchable medicine (available separately) according to the prescribed dosage;
[0046] Cartridge refers to standardized containers with multiple slots. Each slot holds one unit of a substance, medicine and/or flat tab and each cartridge holds only one type or brand name of the substance, medicine and/or flat tab
[0047] Individual Unit refers to one singular unit of a particular type of medicine without removing the manufacturer's packaging;
[0048] Manufacturing Information refers to information (including the batch number and expiry date) printed by the manufacturer on each strip of medicine;
[0049] Order ID refers to the distinct identification number of a specific order in relation to a particular patient and contains information in respect of medicines, prescriptions and dosage instructions obtained directly from customers and approved by pharmacists. The order ID is derived from aggregate information recorded in a proprietary database categorised by identification numbers;
[0050] Non-pouchable Medicines refers to (1) all medicines that are not packaged by the manufacturer in strips, and are marketed in other forms such as bottles and vials; (2) pills required to be consumed in half or partial quantities; and (3) any medicine for which the manufacturer's packaging is required to be disrupted in to enable its consumption in exact quantities due to its form, dosage or prescription;
[0051] Order refers to the sequence of dose pouches for tenure of time interval, as specified by the customer/patient. It may be 15 days or 30 days or any specified number of as provided by customer/patient;
[0052] Pouch refers to the container which is made up of materials including but not limited to plastic that envelopes the pouch load and bears a printed label containing details in respect of each medicine in the pouch load, including the (1) day, date and time of dosage; (2) food directions for dose consumption; (3) names of the medicines; (4) quantities of medicines; (4) expiry dates of medicines; and (5) bar code or identification number of the pouch;
[0053] Pouch Load refers to the exact combination of the various individual units and/or flat-tabs, where necessary;
[0054] Pouchable medicines refers to oral solid medicines (including pills) packaged by the manufacturer in strips; or any medicine for which the manufacturer's packaging is not required to be disrupted to enable its consumption in exact quantities due to its form, dosage or prescription;
[0055] Carefill refers to a paper-back housing that houses the pouches for each refill of the patient.
DESCRIPTION
[0056] The present invention relates to an apparatus for automated sorting and enveloping of homogeneous and/or heterogeneous substances which comprises of: [0057] a tracking unit for tracking homogeneous and/or heterogeneous substances including medicine/drug strips and information on such substance; [0058] a cutting unit to cut homogeneous and/or heterogeneous substances including medicine/drug strips; [0059] a Cartridge with slots for loading of individual units of homogeneous and/or heterogeneous substances including medicine/drug; [0060] a loading bay to load the Cartridges which contain the individual units of homogeneous and/or heterogeneous substances including medicine/drug; [0061] a motor hub for calibrating Cartridge slots for sorting of the individual units of homogeneous and/or heterogeneous substances including medicine/drug; [0062] a conveyor belt to carry the individual units of homogeneous and/or heterogeneous substances including medicine/drug into a pouch forming chute; [0063] a printing unit for labeling of film which is used for forming a pouch; [0064] a horizontal and vertical heat-sealers to seal the pouches for securing the enveloped individual units resulting in four side sealed pouches; [0065] a dispensing unit for dispensing of the sealed and labeled pouches; [0066] a filling unit for filling dispensed pouches into Carefills; and [0067] sensors that track radio frequency based tags, optical machine formats/codes, and/or individual unit movement using micro-stepper motors.
[0068] A schematic representation of a system where the present invention may be implemented is illustrated in
[0077] The top and bottom cameras (1 and 1) carry out imaging and tracking of substances (including pharmaceutical products) retained in the manufacturer's packaging. The imaging is of shape and size recognition of the medicine/drug strip. The optical machine format reader (2) at the top and/or bottom carry out optical character recognition of manufacturer's information printed on the packaging. The first conveyor belt (6) transports the strips to the laser cutting area. The HMI (4) projects relevant grid lines from internal database post recognition from imaging mentioned above. This HMI (4) also allows for adjustment of grid lines by the operator, in case the relevant ones do not exist in the internal database.
[0078] Further, the laser cutters (4) cut the medicine/drug strips into individual units according to projected grid lines. Then, the third camera (5) photographs each cut unit pill from the top. The second conveyor belt (6) and air jet and/or other mechanisms including but not limited to pneumatic pumps and mechanical pushers transport and direct the each cut individual unit into single slots of the Cartridge (8) via a funnel in the same order as they are cut and photographed, to maintain traceability.
[0079] The loading bay holds the Cartridge (8) and rotates it in synchronization with the cutting mechanism. It also houses the Radio frequency based programmer (9) to program the Radio frequency based tag present on the Cartridge (8) with relevant information of the unit pills filled into that Cartridge (8).
[0080]
[0081]
[0082] The outer cover of the Cartridge (8) that has an opening to allow for filling of unit pills into individual slots of each Cartridge, as described in
[0083] The individual slots house individual units of medicines/drugs. The cartridge hub and a motor hub aid the rotation of the Cartridge (8) when loaded on to the motor arm. Further, the motor arm is a part of the loading bay as described in
[0084] Further,
[0085]
[0090] The loading houses all the cartridges and Radio frequency based sensors to confirm the correct and right quantities of the Cartridges have been loaded. The dispensing bay (31) dispenses the relevant individual units onto the conveyor belt and confirms the same with installed sensors. Further, the conveyor belt carries and drops the dispensed individual units into the pouching area and confirms the same with installed sensors at the end of the conveyor belt.
[0091] Thus, the installed sensors: [0092] confirm loading individual units into Cartridge slots; [0093] confirm loading of correct Cartridges and quantities on loading bay [0094] confirm dispensing individual units from Cartridge slots onto the conveyor belt; and [0095] confirm dispensing Pouch load of individual units into labeled pouch;
[0096] Then the printing unit (32) carries out labelling of the tensed enveloping film using a printer. The pouching area carries out pouching of the individual units. Once the exact number of pills are dropped by the conveyor belt fall into the printed part of the enveloping film as detailed in
[0097] The Carefill filling area dispenses all the pre-organised, enveloped and labelled multi-dose pouches of each patient's refill in accordance with their chosen dispensing or delivery cycle. Furthermore, these multi-dose pouches, dispensed in chronological order are automatically filled into a refill also called Carefill. Additionally, the last pouch to enter the said refill, which will eventually be the first pouch that is pulled out by the end user, is a blank pouch that is labelled with the name of the patient, the start date (representing the day the medicines need to start being consumed) and the tenure of the enveloped medicines. Lastly, the assembly also prints and dispenses a label, which is to be manually attached to the back of the refill, which has the same information as on the first blank pouch of each refill.
[0098]
[0099]
[0103] The rotator arms (41) are linked to each Cartridge, that is, each Cartridge is loaded on to one rotator arm. Further, the stepper motor (42) helps the rotator arm (41) to move in synchronization with the complete dispensing mechanism and also helps calibrate the slots of the Cartridges (8) when the Cartridge (8) is rotated by the rotator arm (41). The stepper motor (42) is activated once the stepper motor of the relevant Cartridge is alerted by the internal mechanism to dispense an individual unit.
[0104] The conveyor motor (43) allows the conveyor belt to move in synchronization with the dispensing mechanism to be able to transport the dispensed individual units from each cartridge to the pouching chute as has been detailed in
[0105] The conveyor cleats (44) contain the dispensed unit pills on specific sections of the conveyor belt allowing for easier transportation to the pouching chute and traceability. The frame allows for stability of the mechanisms in the loading and dispensing bay
[0106]
[0113] In the apparatus (20) for automated sorting and enveloping of homogeneous and/or heterogeneous substances, the film roller (51) holds the roll of enveloping film made of plastic or other material. Further, the calendaring apparatus (52) that stretches the enveloping film to create enough tension so it becomes possible to print directly onto the enveloping film.
[0114] The printer present in the printing unit (53) prints directly onto the enveloping film in multiple languages, as directed by the internal mechanism. The printing is carried out in synchronization with the pouching assembly as detailed in
[0115] The fully-automated method for tracking, cutting, sorting, enveloping, labelling and dispensing of individual units of assorted substances, in multi dose pouches, without removing the manufacturer's packaging includes the following steps: [0116] (A) tracking of medicine strips, including capture of images and information like manufacturer's information including name, batch number, expiry date, etc. to be used in the subsequent stages; [0117] (B) cutting of medicine strips into individual units and retaining the manufacturers' packaging, while simultaneously scanning and obtaining relevant images and dimensions of the individual units to be used in subsequent stages; [0118] (C) loading of the individual units into cartridges. Each individual unit is filled in one single slot of the cartridge and each cartridge is tagged with a unique identification (ID) by programming in-built Radio frequency based tag or optical machine readable formats on each cartridge. It is from these cartridges that the individual units are obtained to form correct combinations for consumption in a pouch load according to a prescribed dosage in a subsequent stage; [0119] (D) loading of the cartridges into the loading bay. The loading bay is loaded with the exact number of cartridges required for that specific order along with the exact type of cartridge, checked by scanning the radio frequency based tags or optical machine readable formats on each cartridge; [0120] (E) sorting of individual units, dispensed from relevant cartridges to make pouch loads, exactly according to prescribed dosages; [0121] (F) enveloping and labelling of the pouch load into a labelled pouch meant for dispensing exact quantities and combinations of medicines in a prescribed dosage over a specified period of time in chronological order of consumption; [0122] (G) dispensing the pouches of the order with exact quantities and combinations of medication, without removing the manufacturer's packaging, to the consumer/patient for consumption in chronological order over a specified period of time; and [0123] (H) filling the pouches of one order into Carefills which are then labelled with information about patients/consumers and complete Order;
[0124]
[0125] At step 101, tracking of medicine/drug strips is performed using cameras (1 and 1). The tracking of medicine includes capture of images of medicine/drug strips and collection of information like manufacturer's information including name, batch number, expiry date, etc. along with shape, size and machine readable optical code, if any, of medicine/drug strips.
[0126] At step 102, cutting of medicine strips into individual units is performed using lasers and Human Machine Interface (HMI) (4). During cutting of strips of medicine into individual units, in the manufacturers' packaging is retained. Simultaneously scanning and obtaining relevant images and dimensions of the individual units is performed. Thereafter, installed sensors confirms the dispensing of such individual unit into slots of the Cartridges (8).
[0127] At step 103, individual units are loaded into cartridges, while tracking slot location of such individual units. Each individual unit is filled in one single slot of the Cartridge and each cartridge is tagged with a unique ID by programming the in-built Radio frequency based tag or optical machine readable formats on each cartridge. Further, from these Cartridges (8), the individual units are automatically dispensed to form correct combinations of medicines/drugs for consumption to the patients/end users in a pouch load according to a prescribed dosage.
[0128] At step 104, the cartridges are then loaded into the loading bay. The loading bay is loaded with the exact number of Cartridges required for that specific order along with the exact type of cartridge. It is checked by scanning the radio frequency based tags or optical machine readable formats on each Cartridge ( ).
[0129] At step 105, sorting of individual units is achieved by dispensing from relevant Cartridges (8) to make pouch loads that are exactly according to prescribed dosages. The dispensing of individual units is performed with the help of gravity and use of calibrated cartridge slots. Thereafter, sensors installed at the loading bay (10) confirms the dispensing of such individual unit on to the conveyor belt.
[0130] At step 106, enveloping and labelling of the pouch load into a labelled pouch meant for dispensing exact quantities and combinations of medicines in a prescribed dosage over a specified period of time in chronological order of consumption, is accomplished by dropping of these combination of medicines from the conveyor belt into the pouch forming chute(54). Installed sensors ( ) confirms the dropping of these combination of medicines into the pouch forming chute (54). Further, the pouch forming chute(54) envelops such combination of medicines with pre-labelled film which is labelled using the printing unit (52). Printing of the labels of pouch is done in several languages, including Braille.
[0131] At step 107, dispensing of labelled pouches is executed using motors and without removing the manufacturer's packaging of drugs/medicines. The labelled pouches contain the information for the patient for consumption in chronological order over a specified period of time. Further, the pouches are in the order of consumption by the patients with exact quantities and combinations of medication.
[0132] At step 108, filling of the labelled pouches of one order into Carefills is performed which are then labelled with information about patient/consumer and complete Order.
[0133] Accordingly, the method for automated sorting and enveloping of homogeneous and/or heterogeneous substances which maintains complete traceability of the homogeneous and/or heterogeneous substances is performed. Further, by retaining the manufacturer's packaging of drugs/medicines ensures the safety and efficacy of method for automated sorting and enveloping of homogeneous and/or heterogeneous substances. As a result of above, a user will get a convenient, safer, cost-effective and portable system of multiple-dose medicine management that is both safe and easy for consumer/patient use.
[0134] It should be understood that any of the embodiments of the present system can be implemented by using the economical apparatus for automated sorting, enveloping and tracking of homogeneous and/or heterogeneous substances including pharmaceutical products, which are retained in and/or without manufacturer's packaging, in exact customised quantities and combinations.
[0135] Based on the disclosure and teaching provided herein, a person of ordinary skill in the art will know and appreciate other ways and/or methods to implement embodiments of the present invention. Further, any of the methods describes herein may be totally or partially performed using the abovementioned apparatus, which is configured to perform the steps described herein above.
[0136] It would be obvious to those skilled in the art that, based on the concepts, ideas and issues described herein, several variations of the proposed method being considered as well as for apparatus for automated sorting and enveloping of homogeneous and/or heterogeneous substances with distinctly different steps and process, are possible without deviating from the scope of this invention.
[0137] In conclusion, the present invention provides an improved solution to automated sorting, enveloping and tracking of homogeneous and/or heterogeneous substances including pharmaceutical products. While detailed descriptions of one or more embodiments of the invention have been given above, various alternatives, modifications can be ascertained by a person skilled in the art based on the description given hereinabove. Thus, the above description should not be taken as limiting the scope of the invention.