Note: Descriptions are shown in the official language in which they were submitted.
CA 02708561 2010-06-23
METHOD AND SYSTEM FOR LOADING TABLETS INTO CONTAINERS
FIELD OF THE INVENTION
[0001] The present invention relates generally to methods and systems for
loading
tablets, including micro-tablets, into containers.
BACKGROUND OF THE INVENTION
[0002] Tablets are prevalent in various fields including in the
pharmaceutical,
veterinary and confectionary fields. Tablets can be manufactured in a wide
range of sizes.
For example, typical disc shaped tablets may have diameters in the range of
5mm to
20mm and thicknesses in the range of 3mm to 10mm. One particular category of
tablets is
that of "micro-tablets", which are named as such due to their relatively small
dimensions.
For example, disc shaped micro-tablets may have diameters in the range of 2mm
to 3mm
and thicknesses in the range of 0.6mm to 0.9mm.
[0003] Tablets can be made in a wide variety of cross-section shapes such as
circular
shapes, diamond shapes, arrow-head shapes and hexagonal shapes. Regardless of
the
cross sectional shape, many tablets are formed in a generally flattened shape
with two
opposed sides having typically with significantly larger surface areas than
the other sides.
Typically, those two larger surfaces have opposed sides are oriented generally
parallel to
each other. A common example is a generally disc shaped tablet. Despite having
sides
that may be slightly convex, concave or bevelled with for example bisectional
lines, many
tablets lend themselves to being packaged into a specifically designed and
configured
container, and being held in a "stacked" formation within the container with
the largest
side surfaces of the tablets being adjacent to each other (i.e. the tablets
are generally lying
flat, one on top of another with their largest surface areas generally facing
the largest
surface area of an adjacent tablet).
[0004] Some containers are referred to as cartridges if the container holding
a plurality
of tablets is intended to be used in conjunction with a dispensing device,
such that loaded
tablets can be dispensed from the cartridge by the dispensing device. In many
such
devices, the stacked orientation can help in preventing jamming.
I
CA 02708561 2010-06-23
[0005] A plurality of tablets may be loaded into a container that has a
generally
complimentary cross-sectional area sized and shaped to appropriately receive
and hold
tablets in a stacked configuration. In the aforementioned example, disc shaped
tablets may
lend themselves well to being packaged in a stacked formation in a container
having at
least one longitudinally extending channel or tube that is generally
cylindrically shaped.
Among other things, such a stacked orientation of a plurality of tablets
typically minimizes
the space occupied by tablets and allows a maximum number of tablets to be
loaded into a
given container. Stacking of tablets may also assist in ensuring that a
specific and
predetermined number of tablets are consistently loaded into and held in each
container in
a series of containers.
[0006] In some known types of systems for packaging tablets, loading of the
tablets
into the actual container takes place by allowing the tablets to free fall
under the influence
of gravity into and within a container. The container is generally oriented
such that the
channel is oriented generally vertically and is held stationary during
loading. However,
such a loading of tablets within the channel is unpredictable due to the
inherently random
nature of free fall as tablets fall into these containers. It is far from
certain that the tablet
will come to rest in a flattened stationary orientation within the channel,
such that tablets
will be stacked in a flat configuration against adjacent tablets in the
container. This
unpredictability is even more pronounced with smaller lighter tablets, such as
micro-
tablets which may be subject to a significant degree of turbulence in free
fall and may
encounter more electrostatic interaction with the container. Thus, it is quite
possible that
at the end of the free fall into the container, the tablet will not come to
rest in the flat
orientation required for stacking.
[0007] Accordingly, an improved method and system is desirable which can
enhance
the chances of properly seating tablets in a stacked orientation during the
loading of the
container.
SUMMARY OF THE INVENTION
[0008] According to an aspect of the present invention there is provided a
system for
stacking a plurality of tablets within a container comprising: (a) a container
comprising a
generally elongated channel having a first end and a second end, the first end
being
positioned above the second end and having an aperture for receiving a
plurality of tablets
in series into the channel, the second end providing at least partial support
for a plurality
2
CA 02708561 2010-06-23
of tablets stacked within the channel; (b) a container holding apparatus for
releasably
holding the container; (c) a vibration device operable to apply linear
vibration to the
container while the container is being held by the holding apparatus; and (d)
a tablet
delivery system operable to deliver the plurality of tablets sequentially to
the first end of
the channel; wherein the linear vibration of the container provided by the
vibration device
aligns the sequentially loaded plurality of tablets received into the channel
in a stacked
formation within the channel.
[0009] According to another aspect of the present invention there is provided
a system
for packaging a plurality of tablets comprising: (a) a container comprising a
generally
elongated channel having a first end and a second end positioned below the
first end, the
first end having an aperture for receiving a plurality of tablets in series
into the channel;
(b) a container holding and vibration apparatus operable to hold the container
and
concurrently apply linear vibration in a direction to the container; and (c) a
tablet delivery
system operable to deliver the plurality of tablets in series to the first end
of the container
in a direction that is substantially in alignment with the direction of linear
vibration of the
container; wherein the linear vibration of the container provided by the
vibration device is
operable to align the sequentially loaded plurality of tablets in a stacked
formation within
the channel of the container.
[0010] According to yet another aspect of the present invention there is
provided a
system for packaging a plurality of tablets comprising: (a) a container
comprising a
generally elongated channel having a first end and a second end, the first end
having an
aperture for receiving a plurality of tablets in series into the channel; (b)
a container
holding and vibration apparatus operable to hold the container and
concurrently apply
linear vibration in a direction to the container; and (c) a tablet delivery
system operable to
deliver the plurality of tablets in series in an on-edge orientation to the
first end of the
container in a direction that is substantially in alignment with the direction
of linear
vibration of the container; (d) a tablet detection and counting system for
detecting each of
the plurality of tablets being delivered by the tablet delivery system while
each of the
plurality of tablets in the on-edge orientation; wherein the linear vibration
of the container
provided by the vibration device is operable to align the sequentially loaded
plurality of
tablets in a stacked formation within the channel of the container.
3
CA 02708561 2010-06-23
[0011] According to a further aspect of the present invention there is
provided a
method of loading a container having an elongated channel with tablets, the
method
comprising: (a) loading the channel with a plurality of tablets; (b) applying
linear vibration
to the channel containing the tablets; wherein the linear vibration of the
channel is
operable to align the plurality of tablets in a stacked formation within the
channel.
[0012] According to a still further aspect of the present invention there is
provided a
system of loading a container having an elongated channel with tablets, the
method
comprising: (a) a means for loading the channel with a plurality of tablets;
(b) a means for
applying linear vibration to the channel containing the tablets; wherein the
linear vibration
of the channel is operable to align the plurality of tablets in a stacked
formation within the
channel.
[0013] Other aspects and features of the present invention will become
apparent to
those of ordinary skill in the art upon review of the following description of
specific
embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] In the figures which illustrate by way of example only, embodiments of
the
present invention,
[0015] Figure 1 is a top, left front perspective view of a tablet filling
system in
accordance with a first example embodiment of the present invention;
[0016] Figure 2 is a bottom, left front perspective view of the system of
Figure 1;
[0017] Figure 3 is a top plan schematic view of the system of Figure 1;
[0018] Figure 4 is a cross sectional schematic view of the system of Figure 1,
at A-A
of Figure 3;
[0019] Figure 5 is front elevation view of the system of Figure 1;
[0020] Figure 5a is a perspective view of components of the system of Figure
1.
[0021] Figures 6 is a left side elevation view of the system of Figure 1;
4
CA 02708561 2010-06-23
[0022] Figure 7 is an exploded view of some of the components of the system of
Figure 1;
[0023] Figure 8 is schematic side view of part of system 1 illustrating the re-
orientation of tablets in a cartridge.
DETAILED DESCRIPTION
[0024] With reference to Figures 1-6, a tablet filling system 10 is
illustrated that is
operable to fill a container 146 with a plurality of tablets 32. Tablets 32
may be micro-
tablets and may be one or more of many types of tablet used in a large number
of fields,
including in the pharmaceutical, veterinary or confectionary fields. Tablets
32 to be
loaded into a particular container may each be of the same shape, size and may
also be
made from the same materials. Tablets can be made in a wide variety of cross-
section
shapes such as circular shapes, diamond shapes, arrow-head shapes and
hexagonal shapes.
The tablets may be formed in a generally flattened shape with two opposed
sides having
typically with significantly larger surface areas than the other sides.
Typically, those two
larger surfaces may have opposed sides are oriented generally parallel to each
other, such
as a generally disc shaped tablet. Even though the sides that may be slightly
convex,
concave or bevelled with for example bisectional lines, the tablets may lend
themselves to
being packaged into container 146, and being held in a "stacked" formation
within the
channel of the container with the largest side surfaces of the tablets being
adjacent to each
other (i.e. the tablets are generally lying flat, one on top of another with
their largest
surface areas generally facing the largest surface area of an adjacent
tablet).
[0025] With particular reference to Figure 4, container 146 may be configured
in the
form of a cartridge that is suitable for use with a tablet dispensing device
(not shown).
The specific forms and design of containers that can be loaded using system 10
are
numerous, but do require a channel having an opening at the top end of the
channel 148 to
receive a plurality of tablets 32.
[0026] Container 146 may be formed in a generally flattened cuboid shape and
may
have at least one tube or channel 148 formed in a generally cylindrical shape
extending
longitudinally for at least a portion of the length of the container between
an opening 150
towards a base 151. Container 146 and channel 148 may have a wide range of
dimensions, depending upon the number, shape and size of tablets to be held in
the
CA 02708561 2010-06-23
container, and may have a generally circular cross-section that is large
enough to
accommodate the tablets in a stacked orientation in the channel.
[0027] With reference to Figures 1 and 2, system 10 may consist of several
components including a support frame generally designated 199, a sorting bowl
apparatus
12, a capture wheel apparatus 14 and a cartridge holding and vibration
apparatus 16.
Sorting bowl apparatus 12 and capture wheel apparatus 14 comprise a tablet
delivery
system 15 that delivers tablets to a container (e.g. cartridge) held in
cartridge holding and
vibration apparatus 16.
[0028] Tablet filling system 10 may also include a programmable logic
controller
("PLC") 18 (only shown schematically in Figure 1) to control the operation of
one or more
of the components of system 10. PLC 18 may be, for example, a model CPIL M40DT-
D
made by Omron. PLC 18 may be configured to control the rotation of the
counting/capture wheel of apparatus 14, the starting/stopping of this capture
wheel and the
counting of the tablets 32 as they fall into the cartridge 146.
[0029] System 10 may also include a vibration controller device 19 (shown only
schematically in Figure 1) that may control the vibrators that may be part of
vibrating
bowl apparatus 14 and of the cartridge holding and vibration apparatus 16. The
vibration
of bowl 20 and the vibration of cartridge 146 by respective vibrators may be
both
independently controlled through use for example, of a single RNA vibration
control unit
RNA ESK 2001 UL. This RNA controller can vary the intensity and/or frequency
of the
vibration provided by each of the vibrators.
[0030] Support frame 199 may provide support for at least some of the
components of
system 10. Support frame 199 may include a horizontal, transversely and
longitudinally
extending upper support plate 38 and lower base plate 29 that are
interconnected to each
other by support legs 31a-c. Support plate 38 may thus be supported by legs
31, with legs
31a-c being mounted to a lower horizontal surface 38b of support plate 38 of
frame 199
by, for example, bolts/screws (not shown). Legs 31 a-c may also be
interconnected to base
plate 29 of frame 199, with the bottom surfaces of legs 31 being mounted to
upper surface
29a of base 29 by, for example, bolts/screws (not shown). Support frame 199
may also
include a vertically and longitudinally extending vibration support plate 116.
Support
plate 116 may be interconnected and joined to lower horizontal surface 38b of
lower
support plate 38 by way of, for example, welding, bolts/screws or another
known
6
CA 02708561 2010-06-23
connection mechanism. Support plate 116 may provide support for cartridge
holding and
vibration apparatus 16.
[0031] Sorting bowl apparatus 12 may be mounted on top of upper support plate
38 of
frame 199 and may consist of several components including a bowl 20, a bowl
support
frame 22, and a vibration unit (not shown) that may be housed inside an
oriented
cylindrical housing unit 34 that forms part of bowl support frame 22. Numerous
different
types of known sorting bowl units may be used in system 10. Sorting bowl 20
may, for
example, be a cylindrical, stepped or conical sorting bowl.
[0032] With particular reference to Figures 1, 3 and 4, bowl 20 may have a
base 26
with upwardly directed surfaces 26a and 26b. Bowl 20 may also have a generally
vertically oriented, circumferentially extending side wall 28 having an
inwardly directly
circular surface 28a that generally surrounds base 26. Sorting bowl 20 may be
sized and
configured to be appropriate for receiving therein a plurality of tablets 32.
[0033] With reference to Figures 1 and 3, base 26 may have a generally
circular
edged, upwardly directed raised surface area 26a surrounded by an outer
downwardly
sloped edge surface 26b. Extending between the outer edge of surface 26b and
inner side
wall surface 28a may be located a trough base 33 that extends around the
periphery of
surface 26b proximate inside wall surface 28a of wall 28. Outer trough base 33
may
contain a generally annular channel 30 located and extending around a portion
of the
periphery. Channel 30 may have a generally rectangular cross section and thus
may be
configured for receiving micro-tablets 32 in an on-edge, longitudinally
oriented
configuration. Trough base 33 including the portion containing annular channel
30, may
have a generally clockwise downward gradient. Thus tablets that move into
trough 33 and
into channel 30 may tend to move in a clockwise direction along trough base 33
into
channel 30 and towards an exit aperture 40. Bowl 20 may be made from one or
more of a
wide variety of materials such as aluminium which is anodized. It may be
constructed as a
solid, unitary piece such that base portions 26a and 26b do not rotate.
[0034] Movement of the tablets 32 may be caused solely by the vibration
transferred
from the vibrator unit mounted below the bowl inside housing 34. The channel
30 may be
machined into the upper surface area of the bowl and may be sized/angled to
force the
tablets from a flat position to an "on edge" position as they rotate around
the bowl into and
then clockwise within channel 30. However, in other tablet loading systems,
other types
7
CA 02708561 2010-06-23
of apparatus may be utilized that can deliver tablets sequentially in an on-
edge orientation
to an aperture in the bowl for delivery in an on-edge orientation to capture
wheel 44 of
capture wheel apparatus 14.
[0035] With particular reference to Figure 4, channel 30 of bowl 20 may
terminate at
an aperture 40 that is configured to allow a single tablet 32 at a time, while
maintaining its
generally vertical on-edge orientation, to exit sorting bowl 20. Aperture 40
may thus lead
directly and be positioned to provide an upper opening to a vertically
oriented loading
chute 42. Loading chute 42 may be of appropriate shape and dimensions to
maintain
micro-tablets 32 singly in a series in a vertical on-edge orientation and
provide a conduit
for the tablets 32 to move singly in series from sorting bowl 12 to capture
wheel 44 of
capture wheel apparatus 14. As may be discerned from Figure 4, loading chute
42 may be
configured to hold within it, and maintain for a period of time, a plurality
of tablets 32 in a
stacked vertical, on-edge orientation.
[0036] With reference to Figures 1 and 2, bowl 20 may be supported by a bowl
support frame 22, which may include a vertically oriented cylindrical housing
unit 34 and
support legs 36 that are mounted on upper surface 38a of horizontal plate 38
of support
frame 199. As previously stated, housing unit 22 may enclose the vibration
unit (not
shown) which in turn may be in physical contact with base 26 of bowl 20 so as
to provide
vibration to base 26 of bowl 20. The vibration / drive unit may for example
consist of a
RNA Model SRC-N 160-2R vibrator drive sold by RNA Automated Systems Inc.
Sorting
bowl apparatus 12 may be communication with controller device 19 such that the
vibration
of bowl apparatus 12 may be controlled.
[0037] Lower horizontal surface 34a of housing unit 34 may be interconnected
to and
supported by several longitudinally extending vertical support legs 36, with
support legs
36 being mounted to lower horizontal surface 34a of housing unit 34 by, for,
example
blots/screws (not shown). Support legs 36 may also be interconnected and
supported on
the upper surface 38a of horizontally oriented support plate 38 of support
frame 199 by for
example screws/bolts (not shown).
[0038] With particular reference to Figures 2, 3, 4, 5 and 5a, loading chute
42 may be
formed from opposing inner and outer L-shaped plates 43a, 43b. Plate 43a and
plate 43b
may be positioned in a recess 45 in outer wall 28b of bowl 20. Plate 43a,
plate 43b and
recess 45 may be formed with co-operating portions such that interconnection
and joining
8
CA 02708561 2010-06-23
of plate 43a to plate 43b within recess 45, with upstanding leg of plate 43a
being in
abutment with upstanding leg of plate 43b, will form loading chute 42. For
example, with
reference to Figures 5a, plate 43a, may have a screw hole 41a which may enable
screw
141a to pass horizontally through outer plate 43a into a threaded hole in the
inside surface
of recess 45.
[0039] Similarly, plate 43b, may have screw hole 41b which may enable screw
141b
to pass horizontally through plate 43b horizontally into a threaded hole in
the inside
surface of recess 45. Plate 43b may have a vertically oriented slot (see
Figure 5a) formed
in the outer facing surface to provide chute 42. Inner plates 43a and 43b may
be
interconnected and joined to the lower surface of bottom surface 26 of bowl
20. When
positioned in recess 45, inner plates 43a and 43b are held together in face to
face relation
to each other and chute 42 is formed by the vertical slot in plate 43b. Chute
42 may have
an opening 42a positioned and configured to receive tablets 32 singly in an on-
edge
orientation as they exit bowl 20. Tablets then can pass through chute 42 to
exit opening
42b which can be aligned in a position to deliver tablets to capture wheel 44
of capture
wheel apparatus 14.
[0040] The next component of system 10 to be described in detail is capture
wheel
apparatus 14. Capture wheel apparatus 14 may have several components including
a
capture wheel 44 and a capture wheel support frame 48.
[0041] Capture wheel support frame 48 will be described in detail with
particular
reference to Figures 2, 3, 4, 5, 6 and 7. Capture wheel support frame 48 is
supported in
part on and by a horizontal, generally transversely extending, extension
portion 39 from
plate 38 of support frame 199. Capture wheel support frame 48 may include a
horizontally oriented and generally transversely extending upper support plate
50.
Support plate 50 may be positioned and connected to the upper horizontal
surface of plate
38 including the upper surface of extension portion 39 of support plate 38. A
portion of
upper support plate 50 may overhang extension portion 39 as is illustrated in
Figure 2.
[0042] For example, with reference to Figures 4 and 7, upper support plate 50
may
have screw holes 51 which may enable screws 52 to pass downwards through plate
50 into
threaded holes (not shown) in support frame 38. Support frame 48 may also
include a
generally L-shaped support bracket member 54 which may have a horizontal,
generally
transversely and longitudinally extending base portion 56 and a vertically and
transversely
9
CA 02708561 2010-06-23
extending leg portion 58. Horizontal base portion 56 of L-shaped support
member 54 may
be positioned and connected to the upper horizontal surface of upper support
plate 50. For
example, with reference to Figures 4 and 7, horizontal base portion 56 of L-
shaped support
member 54, may have hole(s) or a slot 60 which may enable screws 62 to pass
downwards
through base portion 56 into threaded holes 64 in upper support plate 50.
[0043] Support frame 48 may also include a vertically extending generally
cuboid
shaped, anchor and spacer block 66 positioned and connected with bolts or
screws 68 that
pass through openings at inner vertically oriented surface of leg portion 58
of L-shaped
support member 54. For example, with reference to Figures 5, 6 and 7, leg
portion 58 of
L-shaped support member 54 may have screw holes 69 which may enable screws 68
to
pass horizontally through leg portion 58 into threaded holes 63 in anchor
block 66.
Support frame 48 may also include a vertically and longitudinally extending
forked plate
member 72 that is positioned adjacent and mounted to the inner surface 66a of
block 66.
On a transversely opposite side of anchor block 66 is a vertically and
longitudinally
extending shoe 74. Forked plate 72 and shoe 74 may be positioned and connected
to
transversely 69 opposite vertical side surfaces 66a, 66b respectively of block
66 and may
be contiguous with inner vertical surface of leg portion 58 of L-shaped
support member.
For example, with reference to Figures 4, 5 and 7, forked plate 72 and anchor
block 66,
may have screw holes 76 and 61 respectively which may enable screws 71 to pass
horizontally through forked plate 72 and anchor block 66 into threaded holes
78 in shoe
74.
[0044] Support frame 48 may also include a horizontal, transversely and
longitudinally
extending connector plate 79 which may be interconnected and joined to the
lower
horizontal surfaces of forked plate 72 and shoe 74. Thus, part of the upper
surface of
connector plate 79 can be held in abutment with the downward facing surface of
block 66.
With reference to Figures 2 , 4 and 7 connector plate 79, may have screw holes
179 which
may enable screws 81 to pass upwardly through connector plate 79 into threaded
holes 83
in shoe 74 and threaded holes (not shown) in forked plate 72. Additionally
dowel pins 159
may be received in openings in plate 79 and in the lower surfaces of forked
plate 72 and
shoe 74. Thus, capture wheel support frame 78 may, with forked plate 72,
provide support
for a servo drive motor 80. Additionally, capture wheel support frame 78 in
conjunction
with shoe 74 may, during rotation of capture wheel 44 hold tablets 32 in slots
92 (see
Figures 4 and 7).
CA 02708561 2010-06-23
[0045] Capture wheel 44 will now be described in detail with particular
reference to
Figures 4, 6 and 7. Capture wheel 44 may be mounted on shaft 197 using a key
197a that
is received in a slot 197b of shaft 197. Wheel 44 may be driven in a clockwise
direction
with intermittent movement, by the drive shaft 197 extending from servo drive
motor 80.
The operation of servo drive motor 80 may be controlled by PLC 18. The angular
position
of capture wheel 44 may be determined by a resolver (not shown) that provides
an
electronic signal to PLC 18 to cause PLC 18 to drive motor 80 to rotate
capture wheel 44
so that the precise rotational positions of the wheel can be provided during
operation.
[0046] Servo drive motor 80 may have an outer housing 180 that has flanged
portions
82. Flange portions 82 may be used to mount motor 80 to outer surface 72a of
forked
plate 72. For example, with reference to Figures 6 and 7, flanged portions 82
of drive
motor 80 may have screw holes 182 which may enable screws 84 to pass
transversely
through flanged portions 82 and into threaded holes 172 in outer surface 72a
of forked
plate 72. Motor 80 may be in communication with PLC 18 such that operation of
motor
80 may be controlled by PLC 18.
[0047] Capture wheel 44 may be constructed in numerous different ways to
provide a
plurality of slots / pockets 92 that are positioned at a fixed radial distance
and that are
angularly spaced about, a central axis of rotation X (Figure 4). For example,
capture
wheel 44 may be constructed by interconnected outer and inner discs 86, 186.
Discs 86,
186 may have similar radii and be vertically oriented and extend generally
longitudinally
to form a composite disc structure of generally uniform outer radius. For
example, with
reference to Figures 4, 6 and 7 inner disc 186 may have screw holes 190 which
may
enable screws 90a to pass transversely through inner disc 186 into threaded
holes 191 in
outer disc 86. Also, inner disc 186 and outer disc 86 may have appropriately
positioned
dowel holes which may enable dowel pins 90b that are received therein, to hold
inner disc
86 and outer disc 186 in stationary relative rotational positions to each
other. The
arrangement of dowel holes can ensure that inner disc 186 and outer disc 86
can only be
assembled in one rotational orientation relative to each other.
[0048] Outer disc 86 may be inscribed with multiple slots / pockets 92
angularly
spaced from each other, for example, by a constant angle of 15 . Slots 92 can
be
configured to be capable of receiving and holding a micro-tablet 32 in an on-
edge
orientation during rotation of capture wheel 44. The sides of slots 92 may be
formed by
11
CA 02708561 2010-06-23
inner surface portions of outer disc 86a and inner disc 86b. Alternate
configurations/constructions are possible for forming capture wheel 44, such
that a
plurality of open slots like slots 92 may be formed at a constant radius, and
spaced around
the periphery of a generally circular disc.
[0049] This aforementioned construction of capture wheel apparatus 14 provides
for
relatively easy assembly and disassembly that, for example, slots may be
readily cleaned
or wheels interchanged so that the system may be easily reconfigured to load
different size
and/or shaped tablets. Additionally, it should be noted that the width of slot
92 may be
readily modified by providing for a shim disc having a configuration like
inner disc 86,
that may be interposed between outer disc 186 and inner disc 86.
[0050] It has been found to be of benefit if the material from which inner
disc 186 and
outer disc 86 are formed do not have an affinity that attracts the tablets 32
(i.e. the material
can be chosen so that tablets 32 tend not to stick in slots 92 and so can be
readily
discharged from slots 92). Polished aluminium has been found to be one such
suitable
material for inner disc 186 and outer disc 86.
[0051] Shoe 74 may have a complimentary generally inwardly facing arcuate
surface
74a (Figure 7) of slightly larger radius than capture wheel 44 and be
positioned to
maintain micro-tablets 32 in slots 92 during rotation of capture wheel 44 as
it rotates with
intermittent movement from a generally 12 o'clock or zero degrees position,
through to an
approximately 6 o'clock or 180 degree position. Shoe 74 may be configured such
that it
blocks the openings to slots 92 between approximately 15-30 degrees to about
180
degrees, to counteract the forces resulting from rotation and gravity that
tend to try to
expel each tablet 32 from its respective slot 92.
[0052] With reference to Figures 4 and 7, shoe 74 may be formed with a main
body
portion 178 and a lower face plate portion 94b with a detachable face plate
portion 94a.
Plate portion 94a can be positioned and attached in face-to-face relationship
with plate
portion 94b. Face plate 94a may be releasably connected to face plate portion
94b. For
example, with reference to Figure 7, face plate 94a may have screw holes 98
which may
enable screws 100 to pass transversely through face plate 94a into threaded
holes 102 in
face plate 94b. Additionally face plate 94a and face plate portion 94b may
have holes
106a, 106b, at their inner facing surfaces which enable dowel pins 104 to be
received into
holes 106a of face plate 94a and holes 106b in face plate 94b. The
corresponding non-
12
CA 02708561 2010-06-23
removable main body portion 178 of shoe 74 may be formed with a vertically
oriented
channel that constitutes a feed chute 96 of appropriate configuration to
maintain micro-
tablet 32 in an on-edge orientation as each tablet 32 in sequence leaves its
respective
pocket 92 in capture wheel 44 and travels downwards through feed chute 96
towards
cartridge 146. As shown in Figure 4, feed chute 96 may have an upper
vertically oriented
portion 97 and a lower non-vertical oriented portion 99 that may be oriented
at an angle of,
for example, 30 from the vertical. Non-vertical portion 99 may be oriented
such that it is
in alignment with a channel 148 of cartridge 146 when the cartridge is held in
cartridge
holding and vibration apparatus 16 such that tablets 32 discharged from feed
chute portion
99 will move in such a direction and path that they will be received into
channel 148 of
cartridge 146.
[0053] With reference again to Figure 4, feed chute 96 may have associated
with it, a
micro-sensor device 108 capable of detecting passing micro-tablets 32. Micro-
sensor 108
may have an optical sensing device. Micro-sensor device 108 may provide an
electronic
sensing eye (not shown) with an electronic beam that extends within and across
the
channel within feed chute 96. The beam may be oriented generally horizontally.
Micro-
sensor 108 can be selected to be of sufficiently high-speed and sensitivity to
detect when
tablets 32 successively pass down through feed chute 96. Detection of a tablet
passing
through chute 96 may be assisted by the configuration of feed chute 96 which
presents
micro-tablet 32 to micro-sensor 108 in on-edge orientation thereby presenting
the largest
face of micro-tablet 32 to micro-sensor 108 for detection. Micro-sensor 108
may be a
model FU53TZ optical fiber sensor and an amplifier model VS-V33, both made by
Keyence Corporation.
[0054] When a tablet 32 passes the electronic beam, it may be broken causing a
signal
to be sent by micro-sensor 108 to PLC 18. Micro-sensor 108 may obtain an
optical signal
from the sensing eye which is then converted to a digital signal that may also
be amplified.
The sensor device 108 will be in electronic communication with PLC 18 such
that the
digital signal generated by sensor device 108 can be sent to PLC 18. PLC 18
may also be
operable to function as a counting device to keep count of the number of
tablets passing
through feed chute 96 and thus will track how many tablets have been loaded
into a given
cartridge 146 held in cartridge holding and vibration apparatus 16.
13
CA 02708561 2010-06-23
[0055] The next component of system 10 to be described in detail is cartridge
holding
and vibration apparatus 16. Cartridge holding and vibration apparatus 16 may
consist of
several components including a cartridge holder 112 and cartridge support
frame 114.
Support frame 114 will now be described in detail with particular reference to
Figures 2, 5
and 6. Cartridge support frame 114 may include an inner support plate 118
joined to
downwardly depending support plate 116 of frame 199. Support plate 118 may
also be
joined to an outer support plate 124. Inner support plate 118 may be a
longitudinally and
vertically extending movable plate mounted to the vertically and
longitudinally extending
outer surface of support plate 116. Support plate 118 may be configured to be
capable of
longitudinal movement relative to support plate 116 of frame 199. With
particular
reference to Figure 5, plate 118 may have a longitudinally elongated aperture
120 which
may enable a screw 122 that is attached to and extends outwardly from plate
116 to pass
transversely through plate 118 into a threaded hole (not shown) in plate 116.
The
movement of screw 122 in longitudinally elongated aperture 120 allows for the
adjustment
of plate 118 in the longitudinal direction relative to plate 116.
[0056] Vertically and longitudinally oriented and extending plate 124 may be
mounted
at the vertically and longitudinally extending outer surface 118a of plate
118. Plate 124
may be mounted to plate 118 for vertical movement relative to plate 118. For
example,
with reference to Figure 5, plate 124 may have a pair of spaced, vertically
oriented and
elongated apertures 126. Apertures 126 may enable a corresponding screw 128 to
pass
transversely through plate 124 into threaded holes (not shown) in plate 118.
Vertically
elongated apertures 126 allow for the movement of plate 124 in a vertical
direction
relative to plate 118.
[0057] Extending horizontally and transversely outwards from plate 124 may be
a
shaft 130. Shaft 130 may have mounted around it a cartridge positioning device
133.
Cartridge positioning device 133 may include an 0-clamp device 134 that may be
releasable secured to and rotated about shaft 130. It will be appreciated that
0-clamp may
be rotated relative to shaft 130 and may be positioned securely at varying
axial positions
on shaft 130. As described below, cartridge holding device 112 is secured to 0-
clamp
134. It will the therefore appreciated that by movement of plate 118 relative
to plate 116,
and plate 124 relative to plate 118, provides for two degrees of freedom of
movement of
cartridge holding device 112. The rotational and axial movement of clamp
device 134 on
14
CA 02708561 2010-06-23
shaft 130 extends the type of movement and positioning of cartridge holding
device 112
that is possible.
[0058] By way of further explanation, by translational movement of plates 118
and
124, and rotational and axial movement of 0-clamp device 134, cartridge
holding device
112 can be appropriately positioned and angled for loading of container 146
with tablets
32. For example, cartridge holding device may be positioned such that
container 146 is
oriented longitudinally at an angle of 30 from vertical.
[0059] Cartridge holding device 112 will now be described in detail and
includes a
transversely oriented plate portion 136. The angular position of plate 136 may
be adjusted
by the positioning of 0-clamp 134 on shaft 130, as plate 136 is affixed to a
location on the
outer surface of 0-clamp 134, for example by welding or in a similar known
manner.
[0060] A vibration device 138 may be supported by and connected to plate
portion
136. Vibration device 138 may provide for a vibration of a cartridge 146 held
in holding
device 112. To be able to achieve the desired stacking of tablets 32 in
cartridge 146, the
vibration provided by device 138 includes linear vibration of the cartridge
(i.e. cyclical
forward and backwards movement in the Z direction (see Figure 5). For example,
vibration device 138 may be a linear vibrator model SLV 30 (identification
number
LIN30/8100280) that is distributed by RNA Automation Inc. and may linearly
vibrate in
direction Z at a frequency over a range of 3000-3600 oscillations per minute
with the
amplitude being in the range of 0 to 0.356 mm [i.e. minimum to maximum
amplitude in
each cycle]. It will be appreciated that the frequency and amplitude employed
for the
linear vibration that is required to achieve the desired stacking may vary
depending upon
several variables including the configuration of the particular tablets to be
stacked and the
angle of channel 148 of cartridge 146. The vibration provided by device 138
may be
controlled by controller 19, as referenced above. It may also be possible to
employ
rotational / torsional vibration to cartridge 146 or vibration movement in
other than the Z
direction, so long as it does not interfere with the linear vibration in
direction Z needed to
achieve the stacking of tablets 32 in a flat face to face relationship and it
does not interfere
with delivery of tablets 32 in such a manner that tablets will be received
into opening 150
of cartridge 148.
[0061] With reference again to Figure 5, plate portion 136 of cartridge
holding
apparatus 112, may have screw holes (not shown) which may enable screws 182 to
pass
CA 02708561 2010-06-23
upwards through plate portion 136 and into threaded holes (not shown) in
vibration device
138. A jig or cartridge holder 142 may be supported by and be positioned above
vibration
device 138. For example, with reference to Figures 6 and 7, jig 142, may have
screw
holes 145 which may enable screws to pass generally downwardly through jig 142
and
into threaded holes 144 in vibration device 138.
[0062] Jig 142 may be inscribed so as to form a template of generally
complimentary
shape to micro-tablet cartridge 146. Jig 142 may have portions 142a that
receive cartridge
146 that are made from a flexible and resilient material such that cartridge
146 can be held
by friction fit by jig 142. In this way linear vibrations caused by linear
vibrator 138 may
be communicated to cartridge 146. Other mechanisms can be used to hold
cartridge 146
on jig 142.
[0063] Cartridge 146 may have its cylindrical channel 148 aligned parallel to
the
longest dimension of cartridge 146 and orthogonal to base of cartridge 146.
Channel 148
may be capable of receiving micro-tablets 32 and be in vibration communication
with
linear vibrator 148. The cross-sectional perimeter of container 148 may be of
complimentary dimensions and shape to cross sectional area of micro-tablet 32.
Upper
aperture 150 of container 148 may be positioned at or near lower aperture 101
of feed
chute 96. As referenced above, depending upon the configuration of cartridge
146,
vertical, longitudinal, transverse and rotational adjustments may be made by
way of plates
116, 118 and O-clamp 134 to allow for the angle and position of channel 148 in
cartridge
146 to be varied while keeping upper aperture 150 of container 148 near lower
aperture
101 of feed chute 96. In this way channel 148 of cartridge 146 may be set at
any angle
between approximately 0 and 90 degrees while upper aperture 150 of cartridge
148 is
kept in close proximity to lower aperture 101.
[0064] It will also be appreciated that the use of screws and corresponding
holes,
along with dowel pins with corresponding apertures, as discussed above, helps
ensure that
the various parts are properly oriented with respect to each other. This will
help ensure
that when system 10 is assembled, that everything is precisely oriented to
ensure that the
micro-tablets move properly and reliably through the system.
[0065] Various components of system 10 such as sorting bowl apparatus 12,
capture
wheel apparatus 14, and cartridge holding and vibration apparatus 16 may be
made of
suitable materials such as by way of example only sorting bowl apparatus 12
may be made
16
CA 02708561 2010-06-23
by way of example only from polished aluminium or certain ceramic materials.
Also a
least some of the various components of system 10 such as sorting bowl
apparatus 12,
capture wheel apparatus 14 and cartridge holding and vibration apparatus 16
may be
integrally formed or interconnected to each other by known techniques. For
example if
the components are made of a suitable metal or plastic, welding techniques can
be
employed. Also, the use of screws and/or bolts may be employed.
[0066] The operation of system 10 will now be described in detail. First, an
empty
cartridge 146 that is to be filled with micro-tablets 32 will be placed in jig
142 prior to
starting operation of system 10. Also, a relatively large number of micro-
tablets 32 may
be either by machine or manually pre-loaded into bowl 20 (not shown). Once
system 10 is
made operational (for example by initiating PLC 18 and controller 19 to be
activated)
vibration from vibrator located inside housing 34, gravity and the shape of
the bottom
surfaces 26a and 26b of bowl 20 can cause micro-tablets 32 to vibrate around
the bowl 20
ultimately orienting themselves vertically on-edge in single file in channel
30. Micro-
tablets 32 may move within channel 30 with tablets being aligned in series
within channel
30. Thereafter, one at a time, tablets 32 may move out of bowl 20 via aperture
40 into
loading chute 42, while maintaining their vertical on-edge orientation. When a
slot 92 is
not aligned with the exit aperture from chute 42, a plurality of tablets 32
will remain in
series, each in a vertical, on-edge orientation.
[0067] To load a single tablet 132 into a slot 92, PLC 18 will rotate capture
wheel 44
to a position such that a slot 92 is aligned with the exit aperture 42b from
loading chute 42
(Figure 5a). Then, a single tablet 132 will move from loading chute 42 into an
aligned slot
92. Once a tablet is received in a slot 92, PLC 118 will cause capture wheel
44 to be
rotated. PLC 18 is able to determine the required amount of movement /
rotation that is
required for capture wheel 44 to move to the appropriate next position and can
provide the
appropriate signal to motor 18 to achieve such rotation. It should be noted
that the
subsequent movement of capture wheel 44 may not be completed with the next
slot 92
being aligned with the exit aperture form chute 42. This may, for example, be
because
that subsequent movement was to rotate the capture wheel 44 so that a slot 92
towards the
bottom of capture wheel 44 will be moved into a tablet discharge position.
However,
thereafter, subsequent movement of the capture wheel 44 will eventually result
in indexing
such that the next slot 92 is aligned with the exit aperture 42b from chute 42
so that the
next slot 92 can be filled.
17
CA 02708561 2010-06-23
[0068] It will be noted as shown in Figure 4, that capture wheel 44 may be
configured
such that no slot 92 is presented to loading chute 42 while a slot 92 is
presented to feed
chute 96, and vice versa. In this way, capture wheel 44 can be rotated by
motor 80
clockwise through alternate positions (a) and (b), where position (a) is a
position where a
tablet is fed from chute 42 from bowl 12 and position (b) is a position where
a tablet is
presented to and released into feed chute 96 to deliver a tablet to cartridge
146. In this
way, each slot 92 in capture wheel 44 may in turn be successively filled with
a tablet 32,
and each slot 92 may also be successively emptied of its tablet to pass the
tablet to feed
chute 96.
[0069] PLC 18 may drive motor 80 to rotate capture wheel 44 in a clockwise
direction
and each micro-tablet 32 alternately through positions (a) and (b). In some
embodiments,
positions (a) and (b) may be the same (i.e. one slot 92 may be being filled
from loading
chute 42 while another slot 92 may be being discharged as a tablet moves into
feed chute
96).
[0070] When a micro-tablet 32 is positioned in a pocket 92 that has been
aligned with
feed chute 96, the rotation of capture wheel 44 can eventually cause that
pocket 92 to
become aligned the entrance into feed chute 96 that is formed in the lower
portion of shoe
74. The tablet may then pass into and through feed chute 96 in vertical on-
edge
orientation. During such movement through feed chute 96 it can pass micro-
sensor 108
before exiting chute 96 to drop into container 148 of cartridge 146. As micro-
tablet 32
drops by way of gravity through feed chute 96, micro-sensor 108 may detect
passing
micro-tablet 32 and register the passing of a tablet 32 with PLC 18, such that
a count of
tablets passed to a cartridge 146 held in holding and vibration apparatus 16
can be
maintained. Detection may be facilitated by the shape of feed chute 96 which
presents
micro-tablet 32 to micro-sensor 108 in an on-edge orientation thereby
presenting the
largest surface area of micro-tablet 32 to micro-sensor 108 for detection.
After a
predetermined and specific number of micro-tablets 32 have been counted, PLC
18 may
cause motor 80 to stop rotation of capture wheel 44. In this way, a pre-
determined and
specific number of micro-tablets 32 can be deposited in channel 148 of
cartridge 146. At
this point the filled cartridge 146 may be removed and replaced with an empty
one, the
counter in PLC 18 can be re-set and the capture wheel 44 re-started to begin
the process of
filling the next cartridge 146.
18
CA 02708561 2010-06-23
[0071] It should be noted that while tablets 32 are continuing to be
sequentially loaded
into channel 148 in a vertically on-edge orientation, linear vibration may be
applied to
channel 148 of cartridge 146 by vibration device 138. Due to the combined
effect of (1)
the angle of channel 148 in cartridge 146; and (2) the linear vibration
applied to cartridge
146 in a general Z direction, micro-tablets 32 will tend to move and be re-
oriented to a
position whereby they are oriented in a stacked flat orientation within
channel 148. For
example, with reference to Figure 8, tablets 42a, 42b are shown in their
stacked
relationship to each other within channel 148. Tablet 42c may proceed down the
channel
148 until it contacts with the upward face of tablet 42b. At that point the
effect of the
vibration device will be such as to cause tablet 42c to re-orient itself into
a stacked
relationship with tablets 42a and 42b. Tablet 42d will subsequently follow a
similar path.
It will be appreciated that the linear vibration should be selected to be of a
frequency and
amplitude that it does not cause tablets 42, once re-oriented into a stacked
relationship to
become upset from that orientation.
[0072] In some embodiments filling certain types of tablets, it may not be
necessary
for channel 148 to be oriented at an angle from the vertical. Stacking of the
tablets (into
what would according therefore be a stacked horizontal arrangement) may in
such
embodiments be achieved solely by the linear vibration. In each situation a
person skilled
in the art will be able select the parameters of the frequency and magnitude
of the linear
vibration, and the angle at which the channel 148 of the cartridge is held in
order to
achieve loading of tablets that form a stacked orientation.
[0073] After a pre-determined number of micro-tablets 32 have been counted,
PLC
may send an electronic signal to motor 80 causing motor 80 to stop rotation of
capture
wheel. In this way, a pre-determined and specific number of micro-tablets 32
can be
deposited in channel 148 of cartridge 146. At this point the filled cartridge
146 may be
removed and replaced with an empty one. PLC 18 can be re-set and system 10
restarted
such that capture wheel 44 recommences the process of filling the next
cartridge 146.
[0074] By way of example only, a channel 148 in a cartridge that holds 40
micro-
tablets may be filled in about 30 seconds using a system 10.
[0075] Many variations of the embodiments described above are possible. By way
of
example only, the system could, with some modifications, function with
containers 148
oriented at angles other that 30 and with vibration other than linear
vibration.
19
CA 02708561 2010-06-23
[0076] The systems may also consist of other components that deliver tablets
in series
to a cartridge holding and vibration apparatus like apparatus 16.
[0077] Also, it will be appreciated that the system may be modified to
accommodate
other types of tablets, capsules, pills or similar products.
[0078] Of course, the above described embodiments are intended to be
illustrative
only and in no way limiting. The described embodiments of carrying out the
invention are
susceptible to many modifications of form, arrangement of parts, details and
order of
operation. The invention, rather, is intended to encompass all such
modification within its
scope, as defined by the claims.
[0079] When introducing elements of the present invention or the embodiments
thereof, the articles "a," "an," "the," and "said" are intended to mean that
there are one or
more of the elements. The terms "comprising," "including," and "having" are
intended to
be inclusive and mean that there may be additional elements other than the
listed elements.
