Methods and systems for automated pharmaceutical container sorting

Patent metadata

Field	Value
Publication number	US-12459685-B2
Application number	US-202217712503-A
Country	US
Kind code	B2
Filing date	Apr 4, 2022
Priority date	May 29, 2018
Publication date	Nov 4, 2025
Grant date	Nov 4, 2025

Abstract

A pharmaceutical order filling system includes an order processing device, an automated dispensing device in communication with the order processing device for dispensing a pharmaceutical into a container. The system includes pallets for transporting containers and a container sorting device in communication with the order processing device, the container sorting device for transferring the containers from the pallets to distribution areas. The container sorting device includes a pallet unloading area for retaining a pallet in a pallet unloading position, an exception conveyor, a standard order conveyor, and a container manipulation device including a gripper assembly for moving containers in order from pallets to the exception conveyor or the standard order conveyor.

First claim

The invention claimed is:

1 . A container manipulation system for a pharmaceutical order, comprising:
a pallet conveyor for moving a plurality of pallets configured to hold a plurality of containers; and a gripper assembly for moving at least one of the plurality of containers from at least one of the plurality of pallets to one of an exception conveyor and a standard order conveyor, wherein a first order of the pharmaceutical order includes a first container and a second container of the plurality of containers, and wherein the gripper assembly moves the first container to the standard order conveyor and then moves the second container to the standard order conveyor with the first container and the second container being sequential on the standard order conveyor and being non-sequential on the at least one of the plurality of pallets.

2 . The container manipulation system of claim 1 , wherein the exception conveyor includes a first exception path and a second exception path; and
wherein the gripper assembly is deployed within a container manipulation device and is configured to move at least one of the plurality of containers to one of the first exception path and the second exception path.

3 . The container manipulation system of claim 2 , wherein the second exception path is configured to receive one of the plurality of containers requiring further inspection.

4 . The container manipulation system of claim 3 , wherein the pallet conveyor raises a group of pallets to be engaged by the gripper assembly in a container unloading area; and
wherein a puck stop rail assembly limits movement of the group of pallets in the container unloading area.

5 . The container manipulation system of claim 1 , wherein the pallet conveyor extends from a controlled access area to a packing device and to an inspection station outside the controlled access area for controlled substances.

6 . The container manipulation system of claim 1 , wherein the exception conveyor includes a first exception path, a second exception path, and a third exception path.

7 . The container manipulation system of claim 1 , wherein the container manipulation system is free of a rotary sortation wheel.

8 . The container manipulation system of claim 1 , wherein the gripper assembly is configured to move the first container from a first pallet of the plurality of pallets and the second container from a second pallet of the plurality of pallets with the first pallet being different than the second pallet.

9 . A container manipulation system for orders including one or more containers, comprising:
a pallet conveyor for moving a plurality of pallets configured to hold a plurality of containers with some containers being held within pucks on the plurality of pallets, the pallet conveyor being configured to move pallets between a container filling area and a container unloading area; a pallet lift to raise a group of the plurality of pallets into the container unloading area; a stop rail assembly to limit vertical movement of the pucks in the group of the plurality of pallets; and a gripper assembly for moving at least one of the plurality of containers from at least one pallet of the plurality of pallets to one of an exception conveyor and a standard order conveyor with the at least one pallet in a raised position in the container unloading area, wherein a first order of a pharmaceutical order includes a first container and a second container of the plurality of containers, and wherein the gripper assembly moves the first container to the at least one standard order conveyor and then moves the second container to the at least one standard order conveyor with the first container and the second container being sequential on the standard order conveyor and being non-sequential on the at least one of the plurality of pallets.

10 . The container manipulation system of claim 9 , wherein the stop rail assembly is configured to engage a puck on the pallet to limit vertical movement of pallet.

11 . The container manipulation system of claim 10 , wherein the stop rail assembly includes an arm contacting a plurality of pucks in the pallet.

12 . The container manipulation system of claim 11 , wherein the arm is elongate to contact each of the pucks in a row on the pallet to prevent the pucks from being lifted with a container by the gripper assembly.

13 . The container manipulation system of claim 12 , wherein the arm is positioned to allow the gripper access to a top of the container.

14 . The container manipulation system of claim 11 , wherein the arm is configured to prevent lifting of two adjacent rows of pucks by the gripper assembly.

15 . A method for performing container manipulation for a pharmaceutical order, the method comprising:
moving a plurality of pallets between a container filling area and a container unloading area, via a pallet conveyor, the plurality of pallets being configured to hold a plurality of containers, and a first subset of the plurality of containers being held within pucks on the plurality of pallets; raising a second subset of the plurality of pallets into the container unloading area, via a pallet lift; limiting vertical movement of the pucks on the second subset, via a stop rail assembly; moving the plurality of containers from at least one pallet of the plurality of pallets to one of an exception conveyor and a standard order conveyor, via a gripper assembly, the at least one pallet being in a raised position in the container unloading area; and moving a first container and a second container to a sequential placement on the at least one standard order conveyor, via the gripper assembly, wherein the first container and the second container are positioned non-sequentially on the at least one pallet, and wherein a first order of a pharmaceutical order includes the first container and the second container of the plurality of containers.

16 . The method of claim 15 , further comprising:
limiting the vertical movement of a first pallet of the second subset, by:
contacting a plurality of pucks on the first pallet, via an arm of the stop rail assembly; and
engaging one of the pucks on the first pallet to limit the vertical movement, via the arm.

17 . The method of claim 16 , further comprising:
extending the arm to contact each of the pucks on the first pallet; and preventing the pucks from being lifted by the gripper assembly with one of the plurality of containers, via the arm being extended.

18 . The method of claim 17 , further comprising:
positioning the arm to permit the gripper assembly access to at least one of the first container and the second container; and in response to positioning the arm, moving the first container and the second container to the sequential placement.

19 . The method of claim 16 , further comprising:
positioning the arm to prevent lifting by the gripper assembly of two adjacent rows of the pucks; and in response to positioning the arm, moving the first container and the second container to the sequential placement.

20 . The method of claim 15 , further comprising:
moving the first container from a first pallet of the plurality of pallets, via the gripper assembly; and moving the second container from a second pallet of the plurality of pallets, via the gripper assembly, the first pallet being different than the second pallet.

Assignees

• Express Scripts Strategic Dev Inc

Inventors

• Hoffman Robert E

Classifications

• B07C5/36

  Sorting apparatus characterised by the means used for distribution {(sorting according to destination B07C3/003, B07C3/02)} · CPC title

• B65G1/1376

  the orders being assembled on a commissioning conveyor · CPC title

• B07C5/34

  Sorting according to other particular properties {(material testing per se G01N; quality control G07C3/14)} · CPC title

• B65D83/0409

  the dispensing means being adapted for delivering one article, or a single dose, upon each actuation (B65D83/0445 takes precedence) · CPC title

• G07F17/0092 Primary

  for assembling and dispensing of pharmaceutical articles (medical dispensers for private use, A61J7/00) · CPC title