Method and Apparatus for Sorting, Counting and Packaging Pharmaceutical Drugs and Other Objects

Abstract

A method and apparatus is provided for handling loose objects having different physical characteristics, such as pharmaceutical drugs including, without limitation, oral solids in the form of pills, tablets, capsules and the like. Loose objects are loaded into individual canisters. A tooling assembly, comprising at least one canister drive mechanism, imaging sensor and package handler is mounted to a gantry assembly, can be translated through the cabinet via the gantry assembly to engage with particular canisters in accordance with unique and dynamic control parameters. Objects are dispensed from a canister directly to the desired packaging, such as a vial or “blister pack.” Additionally, a beneficially stronger blister pack container is provided.

What is claimed: 
     
         1 . An apparatus for dispensing loose objects comprising:
 a) a support frame;   b) a plurality of canisters adapted to hold loose objects disposed within said support frame;   c) a gantry assembly;   d) a dispensing assembly movably disposed on said gantry assembly; and   e) a processor adapted to selectively position said dispensing assembly adjacent to at least one canister and dispense loose objects from said at least one canister.   
     
     
         2 . The apparatus of  claim 1 , wherein said plurality of canisters is in a grid pattern. 
     
     
         3 . The apparatus of  claim 1 , wherein each of said canisters further comprises:
 a) a ramp having a first end and a second end, wherein said ramp is pivotally connected to said canister and pivots about a horizontal axis; and   b) at least one motor for selectively raising and lowering said second end of said ramp.   
     
     
         4 . The apparatus of  claim 3 , wherein a plurality of loose objects are deposited from a canister on a ramp. 
     
     
         5 . The apparatus of  claim 4  wherein said processor measures spacing between said loose objects to track said objects along the length of said ramp and adjusts the position of said ramp to separate said loose objects from each other on said ramp when the spacing between said objects is less than a preset minimum value. 
     
     
         6 . The apparatus of  claim 5 , wherein said separated loose objects are deposited directly from said surface into packaging without said loose objects contacting any intervening surface. 
     
     
         7 . The apparatus of  claim 1 , wherein said dispensing assembly further comprises at least one packaging holder. 
     
     
         8 . The apparatus of  claim 1 , wherein said dispensing assembly comprises at least one optical sensor. 
     
     
         9 . An apparatus for dispensing loose objects comprising:
 a) a plurality of canisters, each of said canisters comprising:
 i. a housing having an opening; 
 ii. a ramp, having a first end, a second end, an upper surface and a longitudinal axis, wherein said ramp is mounted to said housing, and said first end is proximate to said opening and pivots about a substantially horizontal axis; and 
 iii. a linkage assembly connected to said ramp; 
   b) a motorized rail assembly;   c) a dispensing assembly, movably disposed on said motorized rail assembly, comprising:
 i. at least one actuator; 
 ii. at least one drive link connected to said at least one actuator; 
 iii. at least one sensor; and 
 iv. at least one packaging holder; 
   d) at least one processor for positioning said dispensing assembly adjacent to selected canisters and dispensing loose objects from said canisters directly into packaging held by said at least one packaging holder.   
     
     
         10 . The apparatus of  claim 9 , wherein said canisters are disposed in a grid pattern. 
     
     
         11 . The apparatus of  claim 9 , wherein the upper surface of said ramp defines a plurality of planes along the longitudinal axis of said ramp. 
     
     
         12 . The apparatus of  claim 9 , wherein the upper surface of said ramp defines at least two pairs of adjacent planes along the longitudinal axis of said ramp, with an angle being formed between each pair of adjacent planes. 
     
     
         13 . The apparatus of  claim 12 , wherein the angles formed between each pair of adjacent planes decrease in the direction of said first end of said ramp. 
     
     
         14 . The apparatus of  claim 9 , wherein the upper surface of said ramp has a concave shape extending substantially along the entire longitudinal axis of said ramp. 
     
     
         15 . The apparatus of  claim 9 , wherein said at least one sensor comprises at least one optical scanner. 
     
     
         16 . The apparatus of  claim 15 , wherein said at least one optical scanner is directed at the upper surface of said ramp. 
     
     
         17 . The apparatus of  claim 16 , wherein said at least one optical scanner is an area-wide scanner directed at substantially the entire upper surface of said ramp. 
     
     
         18 . The apparatus of  claim 9 , wherein said at least one sensor comprises a machine vision system having a field of view. 
     
     
         19 . The apparatus of  claim 18 , wherein said field of view comprises substantially the entire upper surface of said ramp. 
     
     
         20 . The apparatus of  claim 19 , wherein said field of view comprises at least a portion of said packaging. 
     
     
         21 . An apparatus for dispensing loose objects comprising:
 a) at least one canister comprising:
 i. a housing having an opening; 
 ii. a ramp, having a first end, a second end, a length and an upper surface, wherein said ramp is disposed within said housing, and said first end is proximate to said opening and pivots about a horizontal axis; and 
 iii. a linkage assembly connected to said ramp; 
   b) a dispensing assembly comprising:
 i. at least one actuator; 
 ii. at least one drive link connected to said at least one actuator; 
 iii. at least one sensor; and 
 iv. at least one packaging holder; and 
   c) at least one processor for dispensing loose objects from said canisters directly into packaging held by said at least one packaging holder.   
     
     
         22 . The apparatus of  claim 21 , wherein the upper surface of said ramp defines a plurality of planes along the longitudinal axis of said ramp. 
     
     
         23 . The apparatus of  claim 21 , wherein the upper surface of said ramp defines at least two pairs of adjacent planes along the longitudinal axis of said ramp, with an angle being formed between each pair of adjacent planes. 
     
     
         24 . The apparatus of  claim 23 , wherein the angles formed between each pair of adjacent planes decrease in the direction of said first end of said ramp. 
     
     
         25 . The apparatus of  claim 24 , wherein the upper surface of said ramp has a concave shape extending substantially along the entire length of said ramp. 
     
     
         26 . The apparatus of  claim 21 , wherein said at least one sensor comprises at least one optical scanner. 
     
     
         27 . The apparatus of  claim 26 , wherein said at least one optical scanner is directed at the upper surface of said ramp. 
     
     
         28 . The apparatus of  claim 27 , wherein said at least one optical scanner is an area-wide scanner directed at substantially the entire upper surface of said ramp. 
     
     
         29 . The apparatus of  claim 21 , wherein said at least one sensor comprises a machine vision system having a field of view. 
     
     
         30 . The apparatus of  claim 29 , wherein said field of view comprises substantially the entire upper surface of said ramp. 
     
     
         31 . The apparatus of  claim 29 , wherein said field of view comprises at least a portion of said packaging.