Automated system for selecting packages from a cylindrical storage area

What is claimed is:

1. A system for selecting and delivering packages to fill orders comprising:

a) a generally cylindrical storage area comprised of a plurality of storage area locations, each said location having package holders sized and configured to hold a plurality of individual packages in a manner such that each package can be placed into and removed from said locations, each said location having a distinct (r,.theta.,Y) coordinate;

b) a picker sized and configured to be able to hold packages, select packages from said storage area locations, and place packages in said storage area locations in accordance with computer controlled instructions, said picker having a gripper for grasping and moving the packages and having a picker storage holder sized and configured to hold a plurality of packages in a face to face relationship after the packages have been retrieved from said storage area and prior to delivery of the packages to a desired destination separate from said picker;

c) means for moving said picker to selected storage locations;

d) a computer having at least one memory which contains a program for directing said picker to chosen storage area locations and a database containing at least one (r,.theta.,Y) coordinate location in said storage area for each package held within said storage area, said computer being connected to said picker and said means for moving said picker.

2. The system of claim 1 further including a machine readable label provided on each package, which identifies a content of each package, and a package reader associated with said picker and being positioned for reading said label on at least one package located within said storage area location without removing the package, wherein only packages having like content are stored in each (r,.theta.,Y) coordinate location.

3. The system of claim 2 wherein said label is a bar code and said package reader is a bar code reader.

4. The system of claim 2 wherein said label also contains an expiration date.

5. The system of claim 1 wherein said gripper is a vacuum head.

6. The system of claim 1 also comprising a sensor attached to said picker for determining when the package is grasped by said gripper.

7. The system of claim 1 wherein said picker contains a picker storage holder for holding a plurality of packages selected by said picker.

8. The system of claim 7 wherein said picker storage holder is comprised of at least one storing rod and holes are provided in the packages to permit the packages to be held on said storing rod.

9. The system of claim 1 wherein the storage area is comprised of a plurality of storage racks, said storage racks having a shape corresponding to a section of said generally cylindrical storage area said storage racks each having a plurality of locations, each said location having package holders sized and configured to hold at least one of said plurality of individual packages in a manner such that the package can be placed into and removed from said locations by said picker, each location having a distinct (r,.theta.,Y) coordinate.

10. The system of claim 9 wherein at least one storage rack is removably positioned integral to said generally cylindrical storage area.

11. The system of claim 1 wherein said package holders in said generally cylindrical storage area are comprised of a plurality of rods and a hole is provided in each package to permit the package to be held on said rods.

12. The system of claim 1 also comprising at least one communication port attached to said computer through which a list of packages to be selected can be input and a list of packages selected by the system can be output.

13. The system of claim 1 wherein said memory contains a program for checking compatibility of products in packages selected by said picker with products listed in said database.

14. The system of claim 1 also comprising a conveyor in communication with a transfer device, said transfer device in communication with said picker.

15. The system of claim 14 also comprising a plurality of containers positioned on said conveyor, said containers being sized and positioned to receive packages from said transfer device, said transfer device being positioned to receive said packages from said picker and direct said packages into said containers conveyor.

16. The system of claim 15 wherein said containers have machine readable labels.

17. The system of claim 16 wherein said labels are bar codes.

18. The system of claim 15 also comprising a check station located adjacent said conveyor, said check station having a reader for reading said machine readable labels.

19. The system of claim 18 wherein said reader is connected to said computer in a manner to input information from said machine readable labels; said computer having a program for storing the input information in said memory and for comparing the input information to other information contained in said database.

20. The system of claim 1 wherein the packages contain individual doses of medicine.

21. The system of claim 1 wherein said picker includes at least one gripper that picks the packages; at least one column on which said picker is supported, said picker being able to rotate 360.degree. on said column to pick packages from selected storage locations, which locations are positioned at (r,.theta.) points along the circumference of said storage area, said picker movable vertically along said column by said moving means and said moving means controlled by said computer and in communication therewith.

22. A system for selecting and delivering medicine packages from a holding area to fill orders comprising:

a) a holding area comprised of a generally cylindrical frame having a plurality of support rods, each said support rod sized for holding a plurality of medicine packages, each said support rod also associated with a specified medicine package and holding only like medicine packages, each said support rod further having a distinct (r,.theta.,Y) coordinate location;

b) a picker for picking the medicine packages from said support rods in accordance with instructions received from a computer, said picker being able to access said holding area, said picker also capable of holding a plurality of said medicine packages which have been picked from said holding area;

c) a computer having a database containing an (r,.theta.,Y) coordinate location for all packages in said holding area, said computer able to receive orders for the packages and direct said picker; and

d) a supply structure having a shape corresponding to a section of said generally cylindrical frame, said supply structure further having a plurality of supply support rods which extend from said supply structure to form an (r,.theta.,Y) coordinate system, with each said supply support rod, and medicine package thereon, having a unique (r,.theta.,Y) coordinate, said picker disposed to have access to said supply structure such that a given medicine package on an associated one of said plurality of supply support rods can be picked by said picker to fill a patient's order, or a given medicine package in said supply structure can be picked by said picker to restock an associated support rod in said holding area.

23. The system of claim 22 also comprising a conveyor in communication with a transfer device, said transfer device in communication with said picker, and patient order boxes on said conveyor, such that said picker provides the medicine packages it has picked to fill a given order to said transfer device which directs the medicine packages into an associated one of said boxes on said conveyor.

24. The system of claim 22 wherein said picker comprises at least one gripper that picks said medicine packages; at least one column on which said picker is supported, said picker being able to rotate 360.degree. on said column to pick a given medicine package hanging from a corresponding support rod, to restock a given medicine package on a corresponding support rod; and means for moving said picker vertically along said column, said moving means controlled by said computer.

25. The system of claim 24 wherein each medicine package is provided with a machine readable label, and wherein said picker comprises:

a) a housing;

b) a picker storage holder for storing a plurality of medicine packages attached to said housing;

c) means for obtaining the medicine package, said obtaining means slidingly attached to said housing such that it can move in the "r" direction, which is perpendicular to the Y direction, to pick a medicine package from said support rod when said housing is adjacent to and aligned with said support rod, and can move in the "r" direction to place a picked package on said picker storage holder; and

d) a reader attached to said at least one gripper such that it can read said label on a package to be picked by said obtaining means.

26. The system of claim 25 wherein said label is a bar code, and said reader includes a bar code reader.

27. A system for selecting and delivering packages from a holding area to fill orders comprising:

a) a generally cylindrical holding area having a plurality of support rods for holding packages, each said support rod having a distinct radial, angular and vertical coordinate location and holding a plurality of packages, all packages on each said support rod having the same contents;

b) a picker for picking packages from said support rods in accordance with instructions received from a computer, said picker being able to access said generally cylindrical holding area, said picker comprising:

i) a housing;

ii) a picker storage holder attached to said housing for storing packages;

iii) means for producing a suction;

iv) a suction rod and a suction head in fluid connection with each other and with said suction producing means, said suction rod slidingly attached with respect to the vertical and radial directions to said housing, said suction head maintaining a suction therethrough when said suction producing means is activated, by which a medicine package is picked with suction; and

v) sensor for sensing when a package is properly positioned such that said suction head is then moved to said picker storage holder and deposits the package thereon.

28. The system of claim 27 also comprising a conveyor in communication with a transfer device, said transfer device in communication with said picker, and patient order boxes on said conveyor, such that said picker provides the medicine packages it has picked to fill a given order to said transfer device which directs said medicine packages into an associated one of said boxes on said conveyor.

29. The system of claim 27 wherein said picker storage holder is a storing rod which extends from said housing such that said suction head can deposit a package thereon.

30. The system of claim 28 wherein said picker further comprises valves and pneumatic cylinders for moving said suction rod in the vertical and radial directions; and a vacuum pump for providing suction to said suction rod and suction head sufficient to pick a package from said support rod and then hold it to said suction head.

31. The system of claim 29 wherein said suction head has two faces through which a suction can be drawn, each said face capable of picking a package.

32. The system of claim 31 wherein said two faces are parallel to each other and wherein each package has at least one package face and the packages are held by said storing rod and support rods such that said package face of is parallel to a face of said suction head when said suction head is positioned in front of said package.

33. The system of claim 25 also comprising a support rod sensor attached to said housing and adapted to sense said support rods and said supply support rods when said rods are in proximity to said picker.

34. The system of claim 29 wherein said storing rod is hollow and has at least one aperture therein near to an end for receiving said packages deposited thereon by said suction head, and further comprising a compressed air source connected to said hollow storing rod for providing compressed air into said hollow storing rod and out said at least one aperture.

Description Submit all comments and votes

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an automated system for selecting stored articles. One embodiment of the present invention is an automated system for filling prescriptions and restocking medicines in a pharmacy.

2. Description of Related Art

Many industries store products or parts in a storeroom or storage area and repeatedly select some of the stored items to fill orders or for other uses. Such items may range from small electronic components used by a manufacturer of electronic devices to automotive parts, which vary in size, used by service departments of automobile dealerships. Usually one or more people are employed to retrieve the requested items and to restock new and returned items. These individuals may also be required to confirm that the requested items are compatible with one another and with previously supplied items. If the supplied items are to be billed to a customer or charged to particular internal accounts, the list of items is first written by the requester, and rewritten or entered into a computer database by the storeroom attendant to create an invoice, supply list or other document. In some instances, further generations of the list are made by installers, users or billing clerks. Such methods have built-in opportunities for mistakes every time a list is rewritten and are less efficient than automated systems. Moreover, as labor costs rise and the size of inventory needed to be stored expands, the conventional storeroom and parts department become more and more expensive.

Some businesses have attempted to control costs by limiting inventory through standardization of parts. But such limits are not possible or desirable in some industries, particularly in a hospital pharmacy.

Currently, in large hospital environments, doctors visit patients in nursing units and write out medication orders for each patient. A patient is typically placed on a certain medication which may require multiple doses of medication be administered over a period of a day. Some medications are administered at certain times of the day and possibly at intervals of several hours. Patients may also request certain medications on an elective basis for disorders such as headaches. These requests are included in the doctor's order that is sent from the nursing unit to the central pharmacy of the hospital.

Once an order is received by the pharmacy, it is checked by registered pharmacists and input into the pharmacy information system. These orders reflect not only orders that are added to a particular patient's treatment, but changes in the medication treatment. The pharmacy information system combines this information with the patient's existing medication schedule and develops a patient medication profile. A fill list is generated from that profile. The fill list is a list of all the medications that must be distributed to all patients for the day. This information is sent to the pharmacy printer where a hard copy is generated. Frequently, that hard copy or a copy thereof is sent to the billing department so that the medication can be charged to the patient or his insurer.

At this point, the drugs for a particular patient are hand-picked by either a pharmacist or a pharmacy technician and placed in the particular patient's designated box. A registered pharmacist must then check the accuracy of the patient order before it leaves the pharmacy. Individual patient boxes are then loaded into a large cassette and delivered to the nursing unit.

Approximately 30% of the drugs dispensed each day are returned to the pharmacy unused. Since each drug is individually packaged, the drugs must be returned to the pharmacy stock. Patients are then credited for unused medication. This return and crediting process is a very time-consuming task and requires a significant amount of pharmacy manpower.

In a typical large pharmacy, up to 35 pharmacists and pharmacy technicians are responsible for all aspects of the unit dose dispensing task. Because this process is done manually, a certain amount of error occurs. Studies have estimated that a half-percent error rate is typical in a large hospital. Since a hospital may dispense over 6,000 doses each day, this error rate leads to a significant number of missed or incorrect doses.

Several companies have tried to automate this process through various approaches to the problem. Meditrol utilizes a vending machine approach to dispense the unit dose medications. Each nursing unit must have its own stock of prescription drugs. Nurses key in a patient ID and the drugs for that patient are then dispensed from the vending machine. This system is very expensive because of the necessity of purchasing a machine for each nursing unit. Also, restocking each machine is a very time-consuming task. Implementation of this system requires a complete modification of the current drug dispensing process which many hospitals are reticent to undertake. This system claims no labor-saving advantages from its implementation. This system is covered under U.S. Pat. No. 3,917,045 titled "Drug Dispensing Apparatus" and dated Nov. 11, 1975.

Baxter Travenol offers a dispensing system from Samsung, a Korean company, which dispenses bulk solids into a package which is dispensed to the pharmacist. This system only dispenses the 200 most frequently used solids. A typical hospital pharmacy can contain over 1,500 different medications, many in liquid, syringe or bottle form. These medications cannot be automatically dispensed by this system, but must be manually selected by the pharmacist.

Neither system allows the dispensed medications to be automatically returned to the storage area. Thus, there is a need for an automated system which is able to dispense all dosage forms currently contained in a hospital pharmacy. Medicines should be automatically dispensed by the system per a patient order and placed in individual patient medication boxes for a pharmacist to check. Each drug and each patient box should be individually bar coded so that the accuracy of the dispensing process can be automatically checked by the system. Once drugs are returned to the pharmacy, the system should automatically return each drug to its proper location in inventory and credit the patient's account for the return. One system should also keep a running inventory and notify the user whenever inventory of a particular item drops below a preset level and whether the shelf life of an item has passed. With such a system, a hospital can recognize significant labor savings, as well as savings based on improved accuracy in the dispensing function and better tracking of inventory and expired medications.

In U.S. Pat. No. 5,468,110 which issued from a parent application there is disclosed an automated pharmacy system in which a robot picks unit dose packages from a straight track. This system has worked well in hospitals where a large room is available. However, in hospitals where no large rooms are available it is necessary to remove walls or build an addition to have this automated pharmacy. Additionally, the system may be an ideal solution for smaller hospitals who want to lower their distribution costs. Consequently, there is a need for a compact automated package dispensing system.

SUMMARY OF THE INVENTION

We provide an automated method and apparatus for selecting and restocking items stored in a generally cylindrical storage area. This method is particularly useful for filling patient medication orders in a hospital pharmacy. The stored items must be packaged to be held in a storage rack. Preferably, each package contains a bar code corresponding to the package contents. The items are arranged in a main storage rack so that like items are in the same location and a predetermined location is provided for every item.

We prefer to provide a second rack or a designated, preferably moveable portion of the main storage rack for receipt of new or returned items to be restocked. Such items can be randomly placed on this supply station for transmittal to their respective predetermined locations on the storage rack.

We also provide a means for picking items from and placing items in the storage rack and the supply station. The automated picker preferably is comprised of a gripper assembly mounted on a transport vehicle which moves vertically along a column which can rotate 360 degrees. The gripper assembly has a movable rod or other carrier for holding selected items, at least one vacuum head, and associated controls for gripping and moving selected items. We prefer to provide a bar code reader for reading item packages.

We also prefer to provide a conveyor on which boxes, patient medication trays or drawers can be placed. The conveyor is positioned adjacent to the storage area and a transfer device is provided from the storage area out to the conveyor so that the automated picker can place selected items on the transfer device which directs the items into the appropriate container on the conveyor.

We provide a processing unit with associated memory and data entry peripherals. This computer system receives the list of requested items, directs the automated picker, checks the items selected and prepares reports. Data can be entered manually through a keyboard or bar code reader or electronically through a communication port. Reports may be printed, displayed on a console or transmitted to a memory or another computer for later use.

Other details and advantages of our method and apparatus will become apparent from the description of the preferred embodiments shown in the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, the preferred embodiments of the invention and preferred methods of practicing the invention are illustrated in which:

FIG. 1 is a schematic representation of our present preferred system;

FIG. 2 is a top view illustrating a removable storage structure;

FIG. 2A is a top view illustrating the radial coordinate system;

FIG. 3 is a perspective view of a first type of preferred storage rack;

FIG. 3A is a perspective view of a portion of a second type of preferred storage rack;

FIG. 3B is a perspective view of a portion of a third type of preferred storage rack;

FIG. 4 illustrates a present preferred package;

FIG. 5 is an elevation view of our present preferred system;

FIG. 6 is an elevation view of our present preferred system illustrating a package transfer device;

FIG. 7 is a schematic view of a present preferred gripper assembly;

FIG. 8 is a detailed side view of a present preferred automated picker and gripper assembly;

FIG. 8A is a detailed plan view of the automated picker and gripper assembly of FIG. 6;

FIG. 8B is a perspective view of a cut away section of an alternative embodiment for the tip of the automated picker shown in FIG. 8;

FIG. 9 is a diagram showing a preferred vacuum and pressure line for the automated picker and gripper assembly;

FIG. 10 is a flowchart of the filling process;

FIG. 11 is a flowchart of the check process;

FIG. 12 is a flowchart of the return process; and

FIG. 13 is a flowchart of the restocking process.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings wherein like reference numerals refer to similar or identical parts throughout the several views, and more specifically to FIG. 1 thereof, there is shown a schematic representation of a present preferred system 10 for filling orders, such as prescriptions for patients. The system 10 contains storage racks 12 for holding packages and automated picker 18 for selecting and restocking packages. The storage racks 12 are adjacent to each other and form a generally cylindrical shape. Various storage rack designs can be used and certain present preferred storage racks are shown in FIGS. 3, 3A and 3B.

We prefer that one of the storage racks 12a be removable for use as a supply station as shown in FIG. 2. The system is stacked by removing the rack 12a and manually placing new supplies at selected positions. The rack is returned to its original position. Then the picker 18 removes the new packages and places them in assigned locations. As shown in FIG. 3, each rack 12 has a trapezoidal or rectangular support structure 38, having an open front and back. Running up and down the back are a plurality of back rod supports 36 from which the rods 34 extend. The support structure 38 with rods 34 form an (r,.theta.,Y) coordinate system with each rod 34 and medicine packages 32 thereon having a unique (r,.theta.,Y) coordinate. The radial coordinate system is shown most clearly in FIG. 2A. The ends of the storage rods are positioned along circumference 11 and have distinct coordinates defined by the radius "r," the angle .theta., measured from a preselected zero degree reference point, and vertical location Y. Packages are placed in the storage rack so that each product is located at a known (r,.theta.,Y) coordinate. Since every product is has a known (r,.theta.,Y) location, it is possible to direct an automatic picker to any product location to select a desired item. The packages are segregated within the storage rack so that all packages in any given location have the same contents.

Although we prefer to use racks in which packages are hung on rods, other types of racks can be used for storage racks and supply stations in our system. In FIG. 3A, we show the upper portion of a rack having a support structure with an open front and closed back 42. Attached to the back 42 are sets of brackets 44 positioned to hold packages 48. To be held securely in this rack, such packages must be fairly rigid. Blister cards and boxes can be used. If desired, a hole 40 could be provided in the packages to permit them to be carried on a rod. A top portion of another suitable rack having an open front and closed back 42 is shown in FIG. 3B. This rack has a set of shelves 46, which may be inclined toward back 42. A set of dividers 50 separates groups of packages 48. The racks of FIGS. 3, 3A, and 3B have some common features. First, the packages are held in locations having known (r,.theta.,Y) coordinates. Those coordinates could be single (r,.theta.,Y) values as may correspond to the position of the package holes 40 or a group of (r,.theta.,Y) values defining an entire package. Second, there is sufficient clearance between packages to allow automated picker to select, grab and replace individual packages.

In our system, each package preferably contains only one product, although the product may consist of two or more related items, such as nut and bolt. When installed in a hospital pharmacy, each package preferably contains a single dose of medicine. A present preferred package 32 is illustrated in FIG. 4. Although the package could be a blister card or box, we prefer to use a clear plastic bag having a hole 40 to permit the package to be hung on a rod 34 or 66, shown in FIGS. 3 and 7-9. Each package preferably has a bar code 52 and a written description 56, which identify the contents of the package. A white area 58 can be created on the clear plastic bag over which the written description 56 can be printed, stamped or even handwritten. The bar code and the written description may include not only the name of the product, but also its quantity, weight, instructions for use and expiration date. FIG. 5 represents a clear plastic bag for a unit dose of medicine. We can use a bag having a perforation line 53 for easy opening or a recloseable bag having an interlocking rib type seal 54, or both, as shown in FIG. 4. This type of bag is useful in a hospital pharmacy which buys medicines in large or bulk quantities and must repackage the drugs in individual dose packages. Package 32 can be any desired size. We have used a rectangular package having dimensions indicated by arrows A, B, C and D, wherein A is 3.5 inches, B is 1.0 inch, C is 3.0 inches and D is 0.1875 inches. Alternatively, the package 32 can have A equal 5.0 inches, B equal 1.25 inches, C equal 5.0 inches and D equal 0.1875 inches.

Referring now to FIG. 5 and 6, we provide a column 16 along which the automated picker 18 travels vertically. Many types of drive systems could be used to propel the automated picker 18. Whatever drive system is used should be capable of moving the automated picker 18 vertically in a controlled manner to positions along the column which correspond to the Y coordinates of the packages within the rack. The column 16 is mounted to upper pivot 17 and lower pivot 19 which permits the column 16, and an automated picker 18, to rotate 360 degrees to select packages 32, preferably of the type illustrated in FIGS. 3-4. The automated picker 18 is controlled by a computer 88 and may be connected to a local area network of computers, having a database. The database has the order to be filled and a record of the predetermined locations of each different product in the storage racks 12. The computer 88 guides the automated picker 18 based on information contained in the database, such that the automated picker 18 picks packages 32 according to the order to be filled. The automated picker 18 can also include means, such as a bar code reader 68, as shown in FIGS. 7-8A, for determining the identity 52 of a package 32, or package 48 as shown in FIGS. 3A and 3B, in the storage racks 12, or in a removable storage rack 12A, and providing its identity 52 to the computer 88. The computer 88 guides the automated picker 18 to select the desired packages 32 and deliver them to a package transfer device 22 which deposits them into containers 26 on conveyor 24, shown most clearly in FIG. 6. When the system is installed in a hospital pharmacy, the containers 26 are individual patient boxes in which the patient's medication is delivered from the pharmacy to the appropriate floor or nurses' station. The patient boxes 26 preferably are bar coded with a patient identification code. After a patient's order is filled and the patient box 26 has all the medicine packages called for in the order, a conveyor 24 moves the patient box 26 to a check station 94. An operator uses the check station bar code reader 92 to scan the bar code label on the filled patient box 26, as shown in FIG. 1. The patient identification number is taken from the inputted bar code and the order of the patient is displayed on the check station screen 102 of the check station console 103 connected to the computer or network of computers 88. The operator then scans individual medicine package bar codes in the patient box 26. The medicine packages 32 in the patient box 26 are automatically checked for correctness with respect to the patient list on the station screen 102. If the medicine packages 32 in the box 26 are correct, then the patient box is allowed to continue on towards the ultimate destination and the next filled patient box 26 is then checked. If the medicine packages 32 in the patient box 26 are not correct, then it is determined whether the error, whatever that may be, can be corrected. If the correction can be made, then the record on the check station screen 102 is corrected and the procedure for verifying correctness is then repeated. If the problem cannot be corrected, then the patient box 26 can be manually filled or resubmitted to be filled with missing doses by the system and the computer is notified that the patient's order has not yet been filled.

In the event that a patient does not take all of the medicine which has been prescribed, unused medicine is returned to the hospital pharmacy in the patient box 26. Typically, patient boxes are transferred in a carrier which contains several patient boxes. This carrier is received at a return station 96, as shown in FIG. 1. The patient box 26 is first removed from the carrier returned from a nursing unit. An operator uses the return station bar code scanner 98 to