Continuous dosing and packaging system for pharmaceutical additive manufacturing

Abstract

A high-throughput, high-efficiency, and simplified materializing and packaging system and method for mass production of pharmaceutical units (104) utilizing additive manufacturing. The system and method can materialize, inspect, package, and track pharmaceutical units produced by an additive manufacturing system (900). The materializing and packaging system can include one or more materializing and packaging devices (100). The materializing and packaging devices can include a modular configuration with modules. The individual modules are arranged in any relative order, at any location, and in any number in the materializing and packaging device. The flexibility of the modular configuration allows one or more modules to be removed or added at any given time for reasons such as expansion, downsizing, module repair, module upgrade, and the like. High-throughput can be achieved by operating the materializing and packaging devices independently.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to additive manufacturing technology, and more particularly to a continuous additive manufacturing printing, dosing, and packaging system and corresponding method for the continuous production of pharmaceutical units (e.g., tablets, caplets, prints, etc.). BACKGROUND

[0002] Additive manufacturing, also known as three-dimensional (3D) printing, is a rapid prototyping technique that can involve one or more processes in which materials can be joined or solidified to form a 3D object. Materials (e.g., liquid molecules, powder particles, metal particles, molten polymers, molten plastics, etc.) can be added together, typically layer by layer, based on a digital 3D model. A 3D printing system can be operated by a computer system to control one or more parameters to form the shape and size of the desired 3D object. These parameters can include, but are not limited to, the type of material dispensed, the flow of material, the movement of one or more print nozzles or the movement of a print table, temperature and pressure control.

[0003] Currently, 3D printing technologies include light solidification techniques, powder bonding techniques, and fused deposition modeling (FDM) techniques. In an FDM process, material in the form of a filament is fed through a heated nozzle that melts and extrudes the material onto a surface plane, herein referred to as a post-print film. The heated nozzle or the post-print film can be moved while the melted material is dispensed into the desired shape as instructed by a computer system.

[0004] Other additive manufacturing methods, such as melt extrusion deposition (MED), utilize non-filament materials that are melted and pressurized before being dispensed through one or more print nozzles. In an MED process, an initial material is fed into a processing chamber of a melt extrusion module or a screw extrusion system. The initial material is heated and transformed into a melt. The melt is extruded from a discharge outlet of the processing chamber and directed along the discharge outlet to be extruded from a nozzle of the print module. The melt is then deposited onto a film on a print platform.

[0005] There are several challenges for adapting technologies, such as FDM and MED, for large-scale production of pharmaceutical units (e.g., tablets, caplets, prints, etc.). One of such challenges can be achieving high throughput. For example, a single production batch can undergo multiple processes, including a 3D printing process, a dosing process, one or more inspection processes, one or more packaging processes, and a marking process. The throughput of a production batch can be limited by the slowest process and can be limited by the handling of the production batch between processes. Systems that operate multiple parallel-operating devices can achieve higher throughput at the same print quality, but these systems can be costly to maintain and inefficient and complex to operate.

[0006] Another challenge relates to handling the drug units after the 3D printing process is complete. As noted above, the 3D printing process can involve depositing the molten material on a post-print film. The initially deposited molten material can adhere to the post-print film, thereby temporarily bonding the two together. In order to package the drug units in a drug package (e.g., a blister pack) and / or a drug cartridge, it is necessary to separate the drug units from the post-print film, and to do so in a manner that does not damage or deform the drug units as well as the post-print film.

[0007] Another challenge can be traceability. An advantage of using additive manufacturing to form drug units is the ability to customize the properties of the drug units (e.g., dosage, composition, shape, material, structure, etc.). In mass production, drug units from different production batches can be susceptible to being mixed together, especially when operating devices in parallel. As a result, precise information about the drug units and their associated production processes can be unknown or inaccurate. Having customized drug units can mean that accurate and precise drug unit traceability is needed in order to distinguish between different production batches.

[0008] Accordingly, there is a need for high-throughput, efficient, and streamlined infeed and packaging systems and methods for mass producing drug units using additive manufacturing. There is also a need to ensure that the drug units are not damaged or deformed during the infeed and packaging process. There is also a need to remove defective drug units from the production system. Furthermore, there is a need to accurately trace the drug units. SUMMARY

[0009] Described herein are high-throughput, efficient, and streamlined infeed and packaging systems and methods for mass producing drug units using additive manufacturing. In some embodiments, the mass production of drug units can involve one or more continuous production methods. The disclosed systems and methods can infeed, inspect, package, and trace non-damaged or deformed drug units produced by an additive manufacturing system. The infeed and packaging systems of the present disclosure can be configured to receive drug units that are temporarily connected to a post-print film.

[0010] The infeed and packaging systems can include one or more infeed and packaging devices. Each infeed and packaging device can include multiple modules (e.g., an infeed module, an inspection module, a packaging module, a deformation separation module, or a combination thereof). High-throughput can be achieved by operating the infeed and packaging devices independently and in parallel. In some embodiments, high-throughput can be maximized by including more than one type of module in a given infeed and packaging device, particularly when a given individual module has a lower throughput (compared to other modules). The infeed and packaging systems can include a control module that controls each infeed and packaging device and coordinates the parallel operation of the infeed and packaging devices.

[0011] The control module can also control operations between the modules such that the de-stocking and packaging processes are efficient and simplified. Each of the plurality of modules can be capable of automatically transferring the drug units to another module in a continuous manner. Additionally, the components and processes within each of the plurality of modules can be capable of operating automatically, independently, and continuously. The plurality of modules can utilize robotics, which can simplify the de-stocking and packaging system and method and provide a high degree of flexibility.

[0012] In some embodiments, the de-stocking and packaging system and method can use a stocking / de-stocking robot and an inspection robot that operate in conjunction to separate the drug units from the post-printed film received from the additive manufacturing system. This type of separation can involve the stocking / de-stocking robot gently gripping the drug units while the inspection robot gently peels the post-printed film. The coordinated operation between the two robots and the controlled separation method can ensure that the drug units are not damaged or deformed.

[0013] In some embodiments, the de-stocking and packaging system and method can use a deformation separation module to separate the drug units from the post-printed film received from the additive manufacturing system. This type of separation can involve deforming the post-printed film or a material coupled thereto (e.g., smart material). While the post-printed film or smart material is deformed, the de-stocking system does not contact the drug units. As a result of not contacting the drug units, the drug units are not damaged or deformed.

[0014] The production lot of the disclosed de-stocking and packaging apparatus and de-stocking and packaging system and method can also be segregated. After the drug units are separated from the post-printed film, the inspection module can inspect the drug units to capture certain information, such as one or more characteristics of the drug units (e.g., size, shape, color, weight, defects, etc.). The characteristics and other related information can be stored and linked to the production lot. The de-stocking and packaging apparatus transfers the drug units to a blister machine, which can then package the drug units into a blister package. The de-stocking and packaging apparatus transfers the drug units in the blister package to a marking station. The marking station can mark the blister package with a label that can link the information captured by the inspection module thereto. The blister package can be packaged into a drug cartridge, and the marking station can mark the drug cartridge.

[0015] The drug units of a single production lot can be transferred between the modules without leaving the de-stocking and packaging apparatus. Continuously transferring the drug units of a single production lot between the modules of a given apparatus can ensure that the drug units from different production lots are not mixed together. Additionally, linking the information of both the drug units and the production process to the packaged blister package and drug cartridge can ensure traceability and ensure that the information is accurate and precise.

[0016] An exemplary continuous production system for infeed and packaging of pharmaceutical units from an additive manufacturing system, the system comprising: an infeed / outfeed module for receiving the pharmaceutical units from the additive manufacturing system, wherein the pharmaceutical units are deposited on a post-print film when received from the additive manufacturing system; a detection module for detecting the pharmaceutical units; and a control module for controlling the infeed / outfeed module and the detection module, the control causing the infeed / outfeed module and the detection module to separate the pharmaceutical units from the post-print film.

[0017] In some embodiments, the infeed / outfeed module comprises: an infeed / outfeed robotic suction cup module attachable to and detachable from an infeed / outfeed robot by an automatic tool changer.

[0018] In some embodiments, the infeed / outfeed robotic suction cup module comprises an infeed / outfeed robotic suction cup for picking up the post-print film using suction.

[0019] In some embodiments, the infeed / outfeed robotic suction cup is for holding a new film using suction.

[0020] In some embodiments, the infeed / outfeed module comprises: an infeed / outfeed robotic gripper module attachable to and detachable from an infeed / outfeed robot by an automatic tool changer.

[0021] In some embodiments, the infeed / outfeed robotic gripper module comprises an infeed / outfeed robotic gripper for gripping the pharmaceutical units.

[0022] In some embodiments, the infeed / outfeed module comprises: a film magazine for holding one or more new films.

[0023] In some embodiments, the infeed / outfeed module comprises: a sensor for sensing a height of the one or more new films in the film magazine; and a linear actuator for adjusting the height of the one or more new films in the film magazine.

[0024] In some embodiments, the infeed / outfeed module comprises: a staging station for receiving the pharmaceutical units deposited on the post-print film from the additive manufacturing system.

[0025] In some embodiments, the detection module comprises: a detection robotic module attached to a detection robot.

[0026] In some embodiments, the inspection robot module comprises inspection robot suction cups for holding a set of the drug units using suction.

[0027] In some embodiments, the inspection robot module comprises inspection robot grippers for gripping the post-print film.

[0028] In some embodiments, the inspection robot module comprises inspection robot camera tools for capturing one or more images of a set of the drug units.

[0029] In some embodiments, the inspection module comprises a de-stacking station for receiving the drug units deposited on the post-print film from the in-feed / de-stacking module.

[0030] In some embodiments, the de-stacking station comprises a plurality of geometric features, wherein the drug units are configured to be positioned in the geometric features.

[0031] In some embodiments, the inspection module comprises a weighing station comprising one or more weighing scales for weighing a set of the drug units, wherein the one or more weighing scales comprise one or more pockets for holding the set of drug units.

[0032] In some embodiments, a spacing between adjacent inspection robot suction cups of the inspection module is equal to a spacing between adjacent pockets of the one or more weighing scales.

[0033] In some embodiments, the inspection module comprises a reject drug bin for holding non-conforming drug units.

[0034] In some embodiments, the inspection module comprises a film recycling box for holding the post-print film after the post-print film is separated from the drug units.

[0035] In some embodiments, the system further comprises a packaging module for labeling, packaging, or both.

[0036] In some embodiments, the packaging module comprises a blister machine for packaging conforming drug units into blister packs.

[0037] In some embodiments, the packaging module comprises a blister pack station for receiving the blister packs after the conforming drug units are sealed into the blister packs.

[0038] In some embodiments, the packaging module comprises a packaging robot module attached to a packaging robot.

[0039] In some embodiments, the packaging robot module comprises a packaging robot suction cup for holding a blister pack, a cartridge, or both, using suction.

[0040] In some embodiments, the packaging robot module comprises a press block for pressing a flap of a cartridge and a glue dispenser for dispensing glue on a cartridge.

[0041] In some embodiments, the packaging module comprises a marking station for marking a blister pack, a cartridge, or both.

[0042] In some embodiments, the packaging module comprises a cartridge assembly station for assembling a cartridge, wherein the cartridge assembly station is configured to hold the cartridge while one or more blister packs are placed in the cartridge.

[0043] In some embodiments, the packaging module comprises a palletizing station for holding cartridges after they are sealed.

[0044] In some embodiments, the packaging module comprises a cartridge library for holding cartridges before they are assembled.

[0045] In some embodiments, the control module is configured to control operation of the infeed / outfeed module, the detection module, a packaging module, or a combination thereof.

[0046] An example continuous production system for infeeding and packaging pharmaceutical units from an additive manufacturing system, the system comprising: an infeed / outfeed module for receiving the pharmaceutical units from the additive manufacturing system, wherein the pharmaceutical units are deposited on a post-print film when received from the additive manufacturing system; a detection module for detecting the pharmaceutical units; and a deformation separation module for separating the pharmaceutical units from the post-print film.

[0047] In some embodiments, the deformation separation module is a film deformation separation module comprising: a guide slot and an infeed plate for deforming the post-print film, the deformation of the post-print film causing the pharmaceutical units to separate from the post-print film.

[0048] In some embodiments, the film deformation and separation module comprises: a plurality of driving friction wheels and a plurality of driven friction wheels, the plurality of driving friction wheels and the plurality of driven friction wheels are configured to move the post-print film towards the guide slot.

[0049] In some embodiments, the film deformation and separation module comprises: an electric actuator for moving the post-print film towards the guide slot; and one or more pneumatic actuators for pressing the post-print film downwards.

[0050] In some embodiments, the drop plate comprises a plurality of slots configured to receive the drug units after the drug units are separated from the post-print film.

[0051] In some embodiments, the guide slot is configured to receive the post-print film after the post-print film is separated from the drug units.

[0052] In some embodiments, the deformation and separation module is a smart material deformation and separation module, the smart material deformation and separation module comprises: a smart material configured to deform and couple to the post-print film, the deformation of the smart material causes the post-print film to deform, wherein the deformation of the post-print film causes the drug units to separate from the post-print film.

[0053] In some embodiments, the smart material is a piezoelectric material.

[0054] In some embodiments, the deformation of the smart material comprises: stretching the smart material or bending at an end of the smart material.

[0055] In some embodiments, the smart material deformation and separation module comprises a circuit configured to apply one or more signals to the smart material, wherein the one or more signals cause the deformation of the smart material.

[0056] In some embodiments, the control module is configured to control the operation of the feeding / dropping module, the detection module, the packaging module, the deformation and separation module, or a combination thereof.

[0057] In some embodiments, the additive manufacturing system comprises: a material supply module to receive a set of printing materials; a split module comprising a split plate, wherein the material supply module is configured to transport a single stream corresponding to the set of printing materials to the split plate, wherein the split plate comprises a plurality of channels to split the single stream into a plurality of streams; a plurality of nozzles; and one or more additive manufacturing controllers to control the plurality of nozzles to dispense the plurality of streams based on a plurality of nozzle-specific parameters.

[0058] In some embodiments, the additive manufacturing system comprises: a first print site comprising a first print platform and a first plurality of nozzles; a second print site comprising a second print platform and a second plurality of nozzles; a film transport mechanism, wherein the system is configured to: determine whether printing of a first portion of each drug unit at the first print site is complete while the post-print film is positioned on the first print platform; identify the second print site in accordance with a determination that printing of the first portion is complete at the first print site; transport the post-print film from the first print platform to the second print platform via the film transport mechanism; and cause printing of a second portion of each drug unit at the second print site.

[0059] In some embodiments, the on / off module is a first on / off module, the detection module is a first detection module, the first on / off module and the first detection module are comprised in a first on / off and packaging device, the system further comprises: a second on / off and packaging device comprising a second on / off module and a second detection module.

[0060] In some embodiments, the control module is configured to control operation of the first on / off and packaging device, the second on / off and packaging device, or both.

[0061] An exemplary method for continuously offloading and packaging drug units from an additive manufacturing system, the method comprising: offloading using an on / off module, a first drug unit, and a post-print film, wherein the first drug unit is deposited on the post-print film upon being received from the additive manufacturing system, wherein the on / off module comprises an on / off robot that can be attached to and detached from an on / off robot suction cup module and an on / off robot gripper module; separating the first drug unit from the post-print film using the on / off module and a detection module.

[0062] In some embodiments, the detection module includes a detection robot gripper, a detection robot suction cup, and a detection robot camera tool, the method further comprising: detecting the first drug unit after being separated from the post-printed film using the detection module; and determining whether the first drug unit is qualified to produce a qualified drug unit.

[0063] In some embodiments, the method further comprises: packaging the qualified drug unit in a blister pack and a medicine box using a packaging module, wherein the packaging module includes a blister machine, a pressing block, and a glue dispenser.

[0064] In some embodiments, the dropping the first drug unit includes: picking up the post-printed film at a film transport mechanism using the feeding / dropping robot suction cup module.

[0065] In some embodiments, the dropping the first drug unit includes: automatically transporting the post-printed film to a transit station using the feeding / dropping robot suction cup module.

[0066] In some embodiments, the method further comprises: picking up a new film from a film library and transporting the new film to a film transport mechanism using the feeding / dropping robot suction cup module.

[0067] In some embodiments, the method further comprises: printing a second drug unit on the new film using the printing station.

[0068] In some embodiments, the method further comprises: replacing the feeding / dropping suction cup module with the feeding / dropping robot gripper module after the first drug unit and post-printed film have been dropped and before being separated.

[0069] In some embodiments, the separating the first drug unit from the post-printed film includes: clamping the first drug unit using the feeding / dropping robot gripper module.

[0070] In some embodiments, separating the first drug unit from the post-printed film includes: peeling off the post-printed film using the detection robot gripper while the feeding / dropping robot gripper module clamps the drug unit.

[0071] In some embodiments, the method further comprises: placing the drug unit at a dropping station using the feeding / dropping robot gripper module after the first drug unit has been separated from the post-printed film.

[0072] In some embodiments, the method further comprises: automatically transporting the post-printed film to a film recycling box using the detection robot gripper after the first drug unit has been separated from the post-printed film.

[0073] In some embodiments, the detecting the first drug unit includes: capturing a plurality of images of the first drug unit using the inspection robotic camera tool.

[0074] In some embodiments, the detecting the first drug unit includes: measuring a weight of the first drug unit using a weighing station.

[0075] In some embodiments, the determining whether the first drug unit is acceptable includes: using the captured images and the measured weight of the first drug unit.

[0076] In some embodiments, the method further includes: automatically transporting, using the inspection robotic suction cup, unacceptable drug units to a reject bin.

[0077] In some embodiments, the method further includes: automatically transporting, using the inspection robotic suction cup, the acceptable drug units to the blister machine.

[0078] In some embodiments, the packaging the acceptable drug units includes: placing and sealing the acceptable drug units in blister packs.

[0079] In some embodiments, the packaging the acceptable drug units includes: automatically transporting the blister packs to a marking station.

[0080] In some embodiments, the packaging the acceptable drug units includes: marking the blister packs with a QR code using the marking station.

[0081] In some embodiments, the packaging the acceptable drug units includes: automatically transporting the blister packs to a pillbox.

[0082] In some embodiments, the packaging the acceptable drug units includes: packaging the pillbox using the pressing block and the dispensing machine. BRIEF DESCRIPTION OF DRAWINGS

[0083] Figure 1 A plan view of an exemplary continuous additive manufacturing printing, filling, and packaging system is illustrated in accordance with some embodiments.

[0084] Figure 2A A plan view of an exemplary filling and packaging apparatus is illustrated in accordance with some embodiments of the present disclosure.

[0085] Figure 2B A flowchart of an exemplary operation of a filling and packaging apparatus is illustrated in accordance with some embodiments of the present disclosure.

[0086] Figure 2CA plan view of an exemplary drug unit temporarily connected with a post-print film according to some embodiments of the disclosure is illustrated.

[0087] Figure 3A A plan view of an exemplary loading / unloading module according to some embodiments of the disclosure is illustrated.

[0088] Figure 3B A plan view of an exemplary film magazine with (left) and without (right) a securing device according to some embodiments of the disclosure is illustrated.

[0089] Figure 3C A side view of an exemplary loading / unloading robot suction cup module according to some embodiments of the disclosure is illustrated.

[0090] Figure 3D A side view of an exemplary loading / unloading robot gripper module according to some embodiments of the disclosure is illustrated.

[0091] Figure 3E A flowchart of exemplary operation of a loading / unloading module according to some embodiments of the disclosure is illustrated.

[0092] Figure 3F A flowchart of exemplary operation of a loading / unloading module cooperating with a detection module to separate a drug unit from a post-print film according to some embodiments of the disclosure is illustrated.

[0093] Figure 4A A plan view of an exemplary detection module according to some embodiments of the disclosure is illustrated.

[0094] Figure 4B A plan view of an exemplary detection robot module according to some embodiments of the disclosure is illustrated.

[0095] Figure 4C A flowchart of exemplary operation of a detection module separating a post-print film from a drug unit according to some embodiments of the disclosure is illustrated.

[0096] Figure 4D A plan view of an exemplary detection robot gripper holding a post-print film according to some embodiments of the disclosure is illustrated.

[0097] Figure 4E A flowchart of exemplary operation of a detection module detecting a drug unit and automatically transporting the drug unit according to some embodiments of the disclosure is illustrated.

[0098] Figure 4F A flowchart of exemplary operation of a detection camera tool capturing images of a set of drug units according to some embodiments of the disclosure is illustrated.

[0099] Figure 4G A plan view of an exemplary detection robot camera tool that captures images of a set of pharmaceutical units is illustrated in accordance with some embodiments of the present disclosure.

[0100] Figure 4H A flowchart of exemplary operations of weighing a set of pharmaceutical units in a weighing station is illustrated in accordance with some embodiments of the present disclosure.

[0101] Figure 4I A flowchart of exemplary operations of automatically transporting non- conforming pharmaceutical units to a reject bin is illustrated in accordance with some embodiments.

[0102] Figure 4J A flowchart of exemplary operations of automatically transporting conforming pharmaceutical units to a blister machine is illustrated in accordance with some embodiments.

[0103] Figure 5A A plan view of an exemplary packaging module is illustrated in accordance with some embodiments of the present disclosure.

[0104] Figure 5B A side view of an exemplary packaging robot module is illustrated in accordance with some embodiments of the present disclosure.

[0105] Figure 5C A flowchart of exemplary operations of a packaging process is illustrated in accordance with some embodiments of the present disclosure.

[0106] Figure 5D A flowchart of exemplary operations of automatically transporting blister packs from a blister packaging station to a marking station is illustrated in accordance with some embodiments of the present disclosure.

[0107] Figure 5E A flowchart of exemplary operations of automatically transporting blister packs from a marking station to a cartoning station is illustrated in accordance with some embodiments of the present disclosure.

[0108] Figure 5F A flowchart of exemplary operations of a packaging module 500 automatically transporting flattened cartons from a carton library to a cartoning station is illustrated in accordance with some embodiments of the present disclosure.

[0109] Figure 5G A flowchart of exemplary operations of unflattening cartons is illustrated in accordance with some embodiments of the present disclosure.

[0110] Figure 5H A flowchart of exemplary operations of sealing cartons is illustrated in accordance with some embodiments of the present disclosure.

[0111] Figure 5IA flowchart illustrating exemplary operations for automatically transporting a drug cartridge to a marking station according to some embodiments of the present disclosure is shown.

[0112] Figure 5J A flowchart illustrating exemplary operations for automatically transporting a drug cartridge from a marking station to a palletizing station according to some embodiments of the present disclosure is shown.

[0113] Figure 6 A block diagram illustrating an exemplary control module according to some embodiments of the present disclosure is shown.

[0114] Figures 7A-7B A plan view and a cross-sectional view of an exemplary film deformation separation module according to some embodiments of the present disclosure are shown, respectively.

[0115] Figure 7C A flowchart illustrating exemplary operations of a film deformation separation module according to some embodiments is shown.

[0116] Figure 8A A cross-sectional view of an exemplary smart material deformation separation module according to some embodiments of the present disclosure is shown.

[0117] Figure 8B A flowchart illustrating exemplary operations of a smart material deformation separation module according to some embodiments of the present disclosure is shown.

[0118] Figure 9A A view of an exemplary additive manufacturing system according to some embodiments of the present disclosure is shown.

[0119] Figure 9B A top view of an exemplary layout of a multi-station 3D printing station for additive manufacturing of drug units according to some embodiments of the present disclosure is shown. DETAILED DESCRIPTION

[0120] Described herein are high-throughput, efficient, and simplified infeed and packaging systems and methods for mass production of drug units using additive manufacturing. The disclosed systems and methods can infeed, package, and track drug units produced by an additive manufacturing system that are not damaged or deformed. The infeed and packaging systems of the present disclosure can be configured to receive drug units temporarily connected with a post-printing film.

[0121] The deblading and packaging system can include one or more deblading and packaging devices. Each deblading and packaging device can include a plurality of modules (e.g., a feeding / deblading module, an inspection module, a packaging module, a deformation separation module, or a combination thereof). High throughput can be achieved by operating the deblading and packaging devices independently and in parallel. In some embodiments, high throughput can be maximized by including more than one type of module in a given deblading and packaging device, particularly when a given individual module has a lower throughput (compared to other modules). The deblading and packaging system can include a control module that controls each deblading and packaging device and coordinates the parallel operation of the deblading and packaging devices.

[0122] The control module can also control the operation between modules such that the deblading and packaging process is efficient and streamlined. Each of the plurality of modules can be capable of automatically transferring a pharmaceutical unit to another module in a continuous manner. Additionally, the components and processes within each of the plurality of modules can be capable of operating automatically, independently, and continuously. The plurality of modules can utilize robotics, which can streamline the deblading and packaging system and method and provide a high degree of flexibility.

[0123] In some embodiments, the deblading and packaging system and method can use a feeding / deblading robot and an inspection robot that operate in coordination to separate a pharmaceutical unit from a post-print film received from an additive manufacturing system. This type of separation can involve the feeding / deblading robot gently gripping the pharmaceutical unit while the inspection robot gently peels the post-print film. The coordinated operation between the two robots and the controlled separation method can ensure that the pharmaceutical unit is not damaged or deformed.

[0124] In some embodiments, the deblading and packaging system and method can use a deformation separation module to separate a pharmaceutical unit from a post-print film received from an additive manufacturing system. This type of separation can involve deforming the post-print film or a material (e.g., a smart material) coupled thereto. While the post-print film or smart material is deformed, the deblading and packaging system does not contact the pharmaceutical unit. As a result of not contacting the pharmaceutical unit, the pharmaceutical unit is not damaged or deformed.

[0125] The production lot of the disclosed blanking and packaging apparatus and blanking and packaging system and method can also be segregated. After the pharmaceutical units are separated from the post-printed film, the detection module can detect the pharmaceutical units to capture certain information, such as one or more characteristics (e.g., size, shape, color, weight, defects, etc.) of the pharmaceutical units. The characteristics and other relevant information can be stored and linked to the production lot. The blanking and packaging apparatus transfers the pharmaceutical units to the blister machine, which can then package the pharmaceutical units into blister packs. The blanking and packaging apparatus transfers the pharmaceutical units in the blister packs to the marking station. The marking station can mark the blister packs with a label, which can link the information captured by the detection module thereto. The blister packs can be packaged into a medicine box, and the marking station can mark the medicine box.

[0126] The pharmaceutical units of a single production lot can be transferred between the modules without leaving the blanking and packaging apparatus. Continuously transferring the single production lot between the modules of a given apparatus can ensure that the pharmaceutical units from different production lots are not mixed together. Moreover, linking the information of both the pharmaceutical units and the production process to the packaged blister packs and medicine boxes can ensure traceability and ensure that the information is accurate and precise.

[0127] The following description presents various embodiments by way of example to enable one of ordinary skill in the art to practice and use the various embodiments. The particular apparatus, techniques, and applications described are meant to be exemplary only. The examples are provided only as examples to increase the understanding of the examples described. As such, it will be apparent to one of ordinary skill in the art that the examples described can be practiced without some or all of the specific details. Other applications are possible, such that the following examples should not be construed as limiting. Various modifications to the examples described herein will be apparent to those of ordinary skill in the art, and the general principles defined herein can be applied to other examples and applications without departing from the spirit and scope of the various embodiments. Thus, the various embodiments are not intended to be limited to the examples described herein but are to be accorded the full scope consistent with the claims.

[0128] Various techniques and process flow steps will be described in detail with reference to the examples illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of one or more aspects and / or features described or referenced herein. However, it will be apparent to one skilled in the art that one or more aspects and / or features described or referenced herein can be practiced without some or all of these specific details. In other instances, well-known process steps and / or structures have not been described in detail in order to not obscure the certain aspects and / or features described or referenced herein.

[0129] In the following description of examples, reference is made to the accompanying drawings, which form a part of the disclosure, in which, by way of illustration, specific examples in which the disclosure can be practiced are described. It is to be understood that other examples can be used and structural changes can be made without departing from the scope of the various examples.

[0130] Although the following description uses the terms "first," "second," etc. to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first detection module can be termed a second detection module, and similarly, a second detection module can be termed a first detection module, without departing from the scope of the various embodiments described. The first detection module and the second detection module are both detection modules, but they are not the same detection module.

[0131] The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms "includes," "including," "comprises," and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0132] As used throughout this disclosure, a reference sign without a letter character following the reference sign can refer to one or more of the corresponding sign, the group of all signs, or some of the signs. For example, "104" can refer to any one of the medicine units (e.g., medicine unit 104A or medicine unit 104H), can refer to all of the medicine units (e.g., medicine units 104A-104H), or can refer to some of the medicine units (e.g., medicine unit 104A).

[0133] Figure 1 A plan view of an exemplary continuous additive manufacturing printing, blanking, and packaging system according to some embodiments is illustrated. The continuous additive manufacturing printing, blanking, and packaging system can include a blanking and packaging device 100 and a multi-position printing station 1000. The blanking and packaging device 100 and the multi-position printing station 1000 are discussed below.

[0134] Exemplary blanking and packaging device overview

[0135] Figure 2A A plan view of an exemplary dosing and packaging apparatus is illustrated in accordance with some embodiments of the present disclosure.

[0136] The dosing and packaging apparatus 100 can be used to dose and depanel pharmaceutical units from an additive manufacturing system. The dosing and packaging apparatus 100 can include a modular configuration having a plurality of modules. In some embodiments, each module can have a robot as its core component. The modular configuration and plurality of modules can allow individual modules to be arranged in any relative order, at any location, and in any number in the dosing and packaging apparatus 100. The flexibility of the modular configuration allows one or more modules to be removed or added at any given time for reasons of expansion, downsizing, module repair, module upgrade, etc.

[0137] The plurality of modules can include, but are not limited to, a dosing / depaneling module 200, an inspection module 300, a packaging module 500, and a control module (e.g., the control module 600 of Figure 6 In some embodiments, the dosing and packaging apparatus 100 can include a deformation separation module (e.g., the film deformation separation module 700 of Figure 7A or the smart material deformation separation module 800 of Figure 8A both of which are discussed below). The dosing and packaging apparatus 100 can utilize the modules to perform one or more functions.

[0138] The additive manufacturing system can include a multi-station printing station 1000, which can be located in any location relative to the dosing system and packaging apparatus 100, so long as the dosing and packaging apparatus 100 has the ability to receive pharmaceutical units (e.g., the pharmaceutical units 104 of Figure 2C discussed below) from the additive manufacturing system. As one non-limiting example, the additive manufacturing system can be located in a position proximate to the dosing / depaneling module 200, as shown in Figure 1 The additive manufacturing system will be discussed in detail below.

[0139] The dosing / depaneling module 200 can be configured to transport pharmaceutical units 104 from one module to another module. For example, the dosing module 200 can be configured to receive pharmaceutical units 104 from an additive manufacturing system. In some embodiments, the pharmaceutical units 104 can be deposited on a post-printing film (e.g., the post-printing film 103 of Figure 2C discussed below) upon being received from the additive manufacturing system. The dosing / depaneling module 200 can be configured to automatically transport the pharmaceutical units 104 to the inspection module 300.

[0140] As used throughout this disclosure, “post-print film” refers to a layer that has been exposed to a 3D printing process and supported a drug unit 104 during the 3D printing process. In some embodiments, during the 3D printing process, the drug unit 104 can be positioned between one or more print nozzles of an additive manufacturing system and the post-print film 103. As used throughout this disclosure, “new film” refers to a film that has not been exposed to a 3D printing process.

[0141] In some embodiments, the infeed / outfeed module 200 can be configured to assist in separating the drug units 104 from the post-print film 103. The infeed / outfeed module 200 can operate in coordination (e.g., in concert) with the detection module 300 to separate the drug units 104 from the post-print film 103. In some embodiments, the coordinated operation can include a control module that controls and coordinates the infeed / outfeed module 200 and the detection module 300 to work together to separate the drug units 104 from the post-print film 103.

[0142] The detection module 300 can be configured to detect the drug units 104. The detection process can be used to determine which drug units 104 are considered to be acceptable and which drug units are considered to be unacceptable (also referred to as unaccepted). An acceptable drug unit 104 can be a drug unit that has one or more characteristics that meet one or more criteria. Exemplary criteria can include, but are not limited to: having a color that is within a predefined color range, having a size that is within a predefined size range, having a shape that is within a predefined size range, having a weight that is within a predefined weight range, having a number of defects that is within a predefined number range. As used throughout this disclosure, a range can include one or more values. In some embodiments, the measured characteristics of the drug units 104 can be compared to different criteria for different drug tablets.

[0143] In some embodiments, the detection module 300 can be configured to transport acceptable drug units 104 to a blister machine 15 of the packaging module 500. In some embodiments, the detection module 300 can automatically transport acceptable drug units 104 to the blister machine 15. The detection module 300 can also be configured to automatically transport unacceptable drug units 104 to a reject bin (e.g., the reject bin 12 discussed below). Figure 4A For example, the reject bin 12 can be included in the detection module 300, so the automatic transportation can occur within the detection module 300.

[0144] Additionally or alternatively, the detection module 300 may be configured to assist in separating the post-printing film 103 from the drug delivery unit 104. The detection module 300 may operate cooperatively with the loading / unloading module 200 to separate the post-printing film 103 from the drug delivery unit 104. In some embodiments, the cooperative operation may include a control module that controls and coordinates the detection module 300 and the loading / unloading module 200 to work together to separate the post-printing film 103 from the drug delivery unit 104.

[0145] The packaging module 500 may include several components, some of which are used for marking, and others for assembly. The packaging module 500 may include a blister packer 15. The blister packer 15 may be configured to package and seal qualified drug units 104 in blister packs. In some embodiments, qualified drug units 104 may be received from the inspection module 300. The blister packer 15 may be configured to transport the sealed blister packs to the blister packing station 420, as discussed in more detail below.

[0146] In some embodiments, the packaging module 500 may be configured to mark blister packs. In some embodiments, the packaging module 500 may be configured to mark pillboxes. Additionally or alternatively, the packaging module 500 may be configured to assemble pillboxes and package one or more blister packs into the pillboxes.

[0147] The feeding and packaging device 100 may also include a control module (e.g., Figure 6 The control module 600 may include one or more computer systems. These computer systems may be used to control the operation of one or more feeding and packaging devices 100. The one or more computer systems may also be used to control the operation of one or more modules of the feeding and packaging device 100. In some embodiments, the one or more computer systems may be used to control the operation of one or more printing stations 1000. As discussed in more detail below, for example, the control module may enable (e.g., by sending control signals) the feeding / unloading module 200 to automatically transport the drug unit 104 deposited on the post-printing film 103 to the detection module 300. As another example, the control module may receive and process one or more signals from one or more sensors, such as those coupled to a film bank (e.g., discussed below). Figure 3B The membrane library 7) is a close-range sensor.

[0148] In some embodiments, the one or more computer systems can be equipped with one or more transceivers for wireless or wired communication with one or more remote systems, such as a server or a remote administrator system. The computer system, the remote system, or both can store information, such as manufacturing date, production lot number, detected characteristics of the drug information, production lot conditions, labels, manufacturing information, and the like.

[0149] To increase the throughput of the dosing and packaging apparatus 100, multiple modules of the dosing and packaging apparatus 100 can be configured to operate simultaneously. For example, the dosing / loading module 200 can be configured to operate simultaneously with the detection module 300. In some embodiments, the dosing / loading module 200 can be configured to operate simultaneously with the blister machine 15. In some embodiments, the detection module 300 can be configured to operate simultaneously with the blister machine 15. In some embodiments, the packaging module 500 can be configured to operate simultaneously with the dosing / loading module 200. In some embodiments, the packaging module 500 can be configured to operate simultaneously with the detection module 300. In some embodiments, the packaging module 500 can be configured to operate simultaneously with the blister machine 15.

[0150] Embodiments of the present disclosure are suitable for large-scale production of drug units. In the case of large-scale production, the dosing and packaging apparatus 100 can manufacture a large number of drug units 104 in multiple production lots. In some embodiments, the multiple modules can be configured to process different production lots simultaneously. For example, the dosing / loading module 200 can be processing a first production lot while the detection module 300 is processing a second production lot. In some embodiments, the dosing / loading module 200 can be processing a first production lot while the blister machine 15 is processing a second production lot or a third production lot. In some embodiments, the detection module 300 can be processing a first production lot while the blister machine is processing a second production lot or a third production lot. In some embodiments, the packaging module 500 can be processing a first production lot while the dosing / loading module 200 is processing a second production lot or a third production lot. In some embodiments, the packaging module 500 can be processing a first production lot while the detection module 300 is processing a second production lot or a third production lot. In some embodiments, the packaging module 500 can be processing a first production lot while the blister machine 15 is processing a second production lot or a third production lot.

[0151] As used throughout this disclosure, the term "simultaneously" means that multiple operations can occur at least partially concurrently. For example, the infeed / outfeed module 200 can begin processing a second production batch, followed by the inspection module 300 beginning processing a first production batch, followed by the infeed / outfeed module 200 completing processing of the second production batch. In this case, at least a portion of the processing of the first production batch by the inspection module 300 occurs simultaneously with at least a portion of the processing of the second production batch by the infeed / outfeed module 200, and thus, multiple modules are operating simultaneously.

[0152] Although this figure illustrates one infeed / outfeed module 200, one inspection module 300, and one packaging module 500, embodiments of the present disclosure are not limited to one of each module, and can include more than one of a given type of module. Additionally, embodiments of the present disclosure are not limited to the same number of each module included in a given infeed and packaging apparatus 100, and can include configurations with more than one of a given type of module. For example, if the inspection module 300 has a slower throughput than the infeed / outfeed module 200, the infeed and packaging apparatus 100 can include two inspection modules 300 (e.g., a first inspection module 300 and a second inspection module 300) and one infeed / outfeed module 200. The infeed / outfeed module 200 can alternately deliver the drug units 104 between the first inspection module 300 and the second inspection module 300. In this case, the throughput of the entire infeed and packaging apparatus 100 can not be limited by the throughput of a single inspection module 300.

[0153] The components and functionality of each module will be discussed in more detail below.

[0154] Exemplary operation of an infeed and packaging apparatus

[0155] Figure 2B A flowchart illustrating exemplary operation of an infeed and packaging apparatus according to some embodiments of the present disclosure is illustrated. The process 150 discusses the overall high-level operation of the infeed and packaging apparatus 100. Detailed information regarding how each module operates is provided below.

[0156] The process 150 can include the process 250, the process 350, and the process 450. More detailed information regarding the high-level overview of each process is provided below. The process 250 can include the infeed / outfeed module 200 infeeding the drug units 104. The infeed and packaging apparatus 100 can receive the drug units 104 from an additive manufacturing system. For example, the additive manufacturing system can place the drug units 104 at a staging location (e.g., the staging location 8 discussed below) of the infeed / outfeed module 200. Figure 3A

[0157] In some embodiments, as Figure 2C ​As shown, the drug units 104 received from the additive manufacturing system can be deposited on the post-print film 103. The post-print film 103 can be any type of material capable of being exposed to a 3D printing process. Those skilled in the art will appreciate that a material capable of being exposed to a 3D printing process would be a material that does not have a deleterious effect on the drug units 104 when exposed, such as outgassing of absorbable substances. In some embodiments, the post-print film 103 can be any type of material capable of withstanding separation from the drug units 104. Those skilled in the art will appreciate that a material capable of withstanding separation from the drug units 104 would be a material that does not break or crack as a result of the separation processes disclosed herein, and does not cause damage to or leave residual material on the drug units 104.

[0158] In some embodiments, the number of drug units 104 in a single production batch can be greater than or equal to 32. In some embodiments, the post-print film 103 can be a material capable of holding the number of drug units 104 in a single production batch.

[0159] Exemplary materials for the post-print film 103 can include, but are not limited to: polyvinyl chloride (PVC) film, low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyethylene terephthalate (PET), polypropylene (PP), polyvinylidene chloride (PVDC), polycarbonate (PC), polyamide (PA), polychlorotrifluoroethylene (PCTFE), and hydroxypropyl cellulose (HPC).

[0160] Referring again to Figure 2B In process 250, the infeed / outfeed module 200 can automatically transport the post-print film 103, with the drug units 104 temporarily connected thereto, to the inspection module 300. In some embodiments, the infeed / outfeed module 200 can place the post-print film 103 and drug units 104 at a staging position of the infeed / outfeed module 200 (e.g., staging position 8 of the infeed / outfeed module 200 discussed below). Figure 3A

[0161] Alternatively, in some embodiments, the infeed / outfeed module 200 can automatically transport the post-print film 103, with the drug units 104 temporarily connected thereto, to a deformation module (e.g., the film deformation separation module 700 or the smart material deformation separation module 800).

[0162] Process 250 can also include the infeed / outfeed module 200 automatically transporting a new film to the additive manufacturing system. The infeed / outfeed module 200 can place the new film at the staging position 8 for pickup by the additive manufacturing system. The new film can be a film that has not yet been exposed to the additive manufacturing system, and thus has not yet had any printing material deposited thereon.

[0163] ​Additionally, in process 250, the drug units 104 can be separated from the post- printed film 103. In some embodiments, the inspection module 300 can receive the post-printed film 103 with the drug units 104 temporarily connected thereto. The loading / unloading module 200 and the inspection module 300 can operate in coordination to separate the drug units 104 from the post-printed film 103.

[0164] Alternatively, the film deformation module 700 can receive the post-printed film 103 with the drug units 104 temporarily connected thereto, and can separate the drug units 104 by deforming the post-printed film 103.

[0165] As another option, the smart material deformation module 800 can receive the post-printed film 103 with the drug units 104 temporarily connected thereto, and can separate the drug units 104 by deforming the material (e.g., smart material) coupled to the post-printed film 103.

[0166] In process 350, the inspection module 300 can be configured to detect one or more characteristics of the drug units 104. The one or more characteristics can include, but are not limited to, color, size, weight, and number of defects. In some embodiments, the characteristics can determine whether any drug product is present in a given drug unit 104, whether there is an issue with the color quality of a given drug unit 104, and what the diameter of a given drug unit 104 is. In some embodiments, the one or more characteristics can be determined by capturing one or more images, determining a weight, or both. In some embodiments, other types of measurements can be employed to determine the characteristics of the drug units 104. For example, the inspection module 300 can be configured to detect the drug units 104 based on height. As another example, the inspection module 300 can be configured to detect the drug units 104 based on the shape of the drug units 104. Additive manufacturing can produce drug units 104 that can have any shape, such as a cylindrical shape or a rectangular shape with rounded corners.

[0167] The characteristics can be used to determine whether a given drug unit 104 is acceptable. As part of process 350, if the drug units 104 are acceptable, the inspection module 300 can automatically transport the acceptable drug units 104 to the blister machine 15. The inspection module 300 can automatically transport one or more acceptable drug units 104 to the blister machine 15 at the same time.

[0168] Also as part of process 350, if the drug units 104 are not acceptable, the inspection module 300 can automatically transport the unacceptable drug units 104 to a reject bin (e.g., the reject bin 320 discussed below). Figure 4Athe defective drug units. The inspection module 300 can automatically transport one or more defective drug units 104 to the waste bin 12 at the same time. In some embodiments, the drug units 104 in the waste bin 12 can be reused or recycled.

[0169] In the process 450, the blister machine 15 can package and seal the qualified drug units 104 in blister packs. In some embodiments, the blister packs can include a plurality of pockets to pocket the qualified drug units 104 as the qualified drug units are packaged into the blister packs. In some embodiments, each pocket can pocket one drug unit 104. The sealed blister packs can be output from the blister machine 15 at the blister pack station 420.

[0170] The process 450 also includes the packaging module 500 automatically transporting the sealed blister packs from the blister pack station 420 to the packaging module 500. The packaging module 500 can use a marking station (e.g., the marking station 14 discussed below Figure 5A of the blister packs. Exemplary labels can include, but are not limited to, barcodes, QR codes, or alphanumeric characters (including letters).

[0171] The packaging module 500 can then automatically transport the marked blister packs to a cartoning station (e.g., the cartoning station 18 discussed below Figure 5A of the blister packs.

[0172] The process 450 can include the packaging module 500 assembling a carton. The packaging module 500 can include a carton library (e.g., the carton library 17 discussed below Figure 5A that holds one or more flat cartons. The packaging module 500 can automatically transport a flat carton from the carton library 17 to the cartoning station 18.

[0173] The packaging module 500 can then assemble the carton. Assembling the carton can include unfolding the carton and folding and sealing flaps of one end (e.g., the bottom end) of the carton.

[0174] One or more blister packs can be placed in the carton. In some embodiments, multiple blister packs can be placed in one carton. Once a target number of blister packs are placed in the carton, the packaging module 500 can seal the carton. Sealing the carton can include folding and sealing flaps of another end (e.g., the top end) of the carton, as discussed in more detail below.

[0175] As part of the process 450, the packaging module 500 can automatically transport the sealed carton to the marking station 14. The marking station 14 can mark the carton. The packaging module 500 can then automatically transport the marked carton to a palletizing station (e.g., the palletizing station 16 discussed belowFigure 5A a palletizing station 16).

[0176] Although Figure 2B An order of the steps discussed above is exemplified, but examples of the present disclosure are not limited to the exemplified order and can include any order. In some embodiments, the order can not be predefined, but the steps can be performed based on one or more conditions, such as whether a robot is available and not performing a step (e.g., to increase throughput).

[0177] Exemplary infeed / outfeed module

[0178] Figure 3A A plan view of an exemplary infeed / outfeed module according to some embodiments of the present disclosure is exemplified.

[0179] The infeed / outfeed module 200 can be used to receive pharmaceutical units 104 from an additive manufacturing system, where the pharmaceutical units 104 are deposited on a post-print film 103 when received from the additive manufacturing system. The infeed / outfeed module 200 can include an infeed / outfeed robot 1, an automated docking tool 6, a staging site 8, a film library 7, an infeed / outfeed robot suction cup module 5, and an infeed / outfeed robot gripper module 4.

[0180] The infeed / outfeed robot 1 can be a robotic arm including a plurality of beams and one or more connecting joints. The infeed / outfeed robot 1 can be capable of movement along a plurality of (e.g., six) degrees of freedom. In some embodiments, the one or more connecting joints can be located between the beams, and the infeed / outfeed robot 1 can have two ends. A first end can be attached to a table-like surface (as shown), and a second end can be capable of having modules attached thereto. For example, the infeed / outfeed robot suction cup module 5 or the infeed / outfeed robot gripper module 4 can be capable of being attached to or detached from the second end of the infeed / outfeed robot 1 through the automated docking tool 6.

[0181] In some embodiments, the automated docking tool 6 can be a quick connect mechanism. The automated docking tool 6 can be located on the back of the infeed / outfeed robot suction cup module 5, and the automated docking tool 6 can be located on the back of the infeed / outfeed robot gripper module 4, the library location 213, and the library location 215.

[0182] The infeed / outfeed robot 1 can be configured to automatically transport post-print films 103 or new films, as discussed in more detail below. In some embodiments, the infeed / outfeed robot 1 can move at a speed of 30-450 cm per minute. In some embodiments, the infeed / outfeed robot 1 can have a repeatability accuracy of +0.03 mm.

[0183] The loading / unloading robot 1 can be configured to receive one or more control signals from a computer system (e.g., one or more computer systems of the control module 600). The control signals can be used to control movement of the loading / unloading robot 1. In some embodiments, the control signals can be used to control movement of the loading / unloading robot suction cup module 5 and movement of the loading / unloading robot gripper module 4. Figure 6

[0184] The staging position 8 can be used to receive a post-print film 103 from the additive manufacturing system. In some embodiments, the staging position 8 can be used to receive a new film from the film library 7, where the new film is to be transported to the additive manufacturing system. The staging position 8 can be a dedicated area located in the loading / unloading module 200. The staging position 8 can be located at a position where the second end of the loading / unloading robot 1 and / or a film transport mechanism of the additive manufacturing system can be able to reach the staging position 8.

[0185] In some embodiments, the staging position 8 can include a surface on which an object (such as a post-print film 103 or a new film) can be placed. In some embodiments, the staging position 8 can have physical characteristics (e.g., dimensions, shape, etc.) determined based on physical characteristics of the post-print film 103, the new film, or both. For example, the surface of the staging position 8 can include a flat surface to have the post-print film or the new film rest on. In some embodiments, the post-print film or the new film can have a curved surface, and the surface of the staging position 8 can have a similarly curved surface.

[0186] In some embodiments, the staging position 8 can have a sensor coupled thereto to determine whether an object (such as a post-print film 103 or a new film) is located at the staging position 8. In some embodiments, the sensor can be a proximity sensor. The sensor can indicate and / or trigger the loading / unloading robot 1 to perform certain steps, such as transporting the post-print film 103 or transporting the new film. In this way, the loading / unloading robot 1 can operate continuously to increase the throughput of the loading / unloading module 200.

[0187] The film library 7 can be used to hold one or more new films. Figure 3B A plan view of an exemplary film library with (left) and without (right) a fixture is illustrated according to some embodiments of the present disclosure. In some embodiments, the one or more new films can be temporarily stored in the film library 7 until ready for use by the additive manufacturing system. In some embodiments, each new film can be stacked at a different z-height within the film library 7 on a base plate 303 between guide posts 305. The film library 7 can include an enclosure 315 that surrounds the edges of the stack of new films in the film library 7.

[0188] ​In some embodiments, one or more sensors 307 and linear actuators (e.g., motor 309 and translation mechanism 311) can be coupled to the film library 7. The sensors 307 can be used to sense the height of a substrate 313 on which new films in the film library 7 can rest. In some embodiments, the sensors 307 can be photoelectric sensors that use signal transmission and reception to determine the height of the new films in the film library 7.

[0189] The linear actuators can be used to adjust the height of the new films in the film library 7. The motor 309 can drive the translation mechanism 311 to move the substrate 303 up and down along the z-direction. The sensors 307 and linear actuators can be configured to ensure that the top surface of the topmost new film in the film library 7 is at a predetermined height. For example, when the on / off loading robot 1 removes the topmost (first) new film from the film library 7, the top surface of the next (second) new film can be at a lower z-height. The sensors 307 can sense this change in height, and the linear actuators can adjust (e.g., raise) the height of the new film to ensure that the top surface of the second new film is at the predetermined height. In this way, the on / off loading robot 1 can not need to adjust the z-height each time to pick up a new film, thereby increasing the throughput of the on / off loading module 100.

[0190] In some embodiments, the film library 7 can also include a plurality of air knives 313. In some embodiments, the new films in the film library can stick together due to electrostatic attraction. The air knives 313 can be configured to blow air between the new films in the film library 7. In this way, the on / off loading robot suction cups (e.g., the on / off loading robot suction cups 102 discussed below) can be prevented from picking up multiple new films from the film library 7 at a given time.

[0191] Another component of the on / off loading module 100 can be an on / off loading robot suction cup module 5. The on / off loading robot suction cup module 5 can be attachable to and detachable from the on / off loading robot 1. Figure 3C A side view of an exemplary on / off loading robot suction cup module 5 according to some embodiments of the present disclosure is illustrated.

[0192] The on / off loading robot suction cup module 5 can be configured to pick up the post-print film 103 using suction. The on / off loading robot suction cup module 5 can include on / off loading robot suction cups 102 located at the front of the on / off loading robot suction cup module 5. The on / off loading robot suction cup module 5 can be used to pick up the post-print film 103 via suction by creating a plurality of negative pressure paths. In some embodiments, the on / off loading robot suction cups 102 can be used to hold the new film using suction. In some embodiments, the on / off loading robot suction cups 102 can have a diameter of 16 mm and a throw distance of 10 mm.

[0193] Although this figure illustrates 10 on / off loading robot suction cups 102, embodiments of the present disclosure can include any number of on / off loading robot suction cups 102, such as 6, 8, 12, 14, 16, 18, 20, etc. In some embodiments, the number of on / off loading robot suction cups 102 can be based on the size of the post-print film 103. Additionally or alternatively, the relative arrangement of the on / off loading robot suction cups 102 can be based on the shape of the post-print film 103 and / or the location of the drug units 104 when deposited on the post-print film 103.

[0194] Other modules can be attached to or detached from the on / off loading robot 1. Figure 3D A side view of an exemplary on / off loading robot gripper module according to some embodiments of the present disclosure is illustrated.

[0195] The on / off loading robot gripper module 4 can be attachable to or detachable from the on / off loading robot 1 and can be configured to grip a drug unit 104. The on / off loading robot gripper module 4 can include on / off loading robot grippers 101 for gripping a drug unit 104. The on / off loading robot grippers 101 can be located at the front of the on / off loading gripper module 4. In some embodiments, each on / off loading robot gripper 101 can be configured to grip one drug unit 104. The on / off loading robot grippers 101 can grip a drug unit 104 by using a jaw to contact and surround the sides of the drug unit 104.

[0196] In some embodiments, the on / off loading grippers 101 can have a holding force of between 7 and 30 Newtons. In some embodiments, the on / off loading grippers 101 can have a holding force of between 9 and 15 Newtons. In some embodiments, the jaws of the on / off loading grippers 101 can have a stroke of 4 mm.

[0197] In some embodiments, the number of on / off loading robot grippers 101 can be equal to or greater than 32. Although this figure illustrates 32 on / off loading robot grippers 101, embodiments of the present disclosure can include any number of on / off loading robot grippers 101, such as 4, 8, 12, 16, etc. In some embodiments, the number of on / off loading robot grippers 101 can be equal to the number of drug units 104 in a single production batch.

[0198] Exemplary operation of an on / off loading module

[0199] Figure 3EA flowchart illustrating exemplary operations of the infeed / outfeed module according to some embodiments of the present disclosure is shown. The infeed / outfeed module 200 can be configured to perform various operations, such as automatically transporting a post-printed film 103, automatically transporting a new film, and automatically separating a drug unit 104 from the post-printed film 103. Each operation of the infeed / outfeed module 200 will be discussed below. The operation of the detection module 300 in step 272 and the operation of the printing station 900 in steps 274 and 276 will be discussed in later sections.

[0200] The infeed / outfeed robot suction module 5 can be attached to the infeed / outfeed robot 1 before the infeed / outfeed module 200 infeeds a drug unit in process 250. In some embodiments, the infeed / outfeed robot suction module 5 can be attached to the infeed / outfeed robot 1 via the automated adapter tool 6.

[0201] In some embodiments, the infeed / outfeed robot suction module 5 can already be attached to the infeed / outfeed robot 1 (e.g., before step 252 begins). In such cases, the infeed / outfeed robot suction module 5 can not need to be reattached to the infeed / outfeed robot 1.

[0202] In cases where the infeed / outfeed robot suction module 5 is not attached to the infeed / outfeed robot 1 before step 252 begins, the infeed / outfeed robot 1 can need to be unattached from the infeed / outfeed robot jaw module 4 (if attached thereto at the time). Unattaching from the infeed / outfeed robot jaw module 4 can include moving the infeed / outfeed robot 1 to the library location 215 and placing the infeed / outfeed robot jaw module 4 at the library location 215 using the automated adapter tool 6. In some embodiments, the infeed / outfeed robot suction module 5 can be stored at the library location 213, and the infeed / outfeed robot 1 can have to move to the library location 213 in order to attach to the infeed / outfeed robot suction module 5.

[0203] Exemplary transportation of a post-printed film

[0204] The infeed / outfeed robot 1 can automatically transport the drug unit 104 and the post-printed film 103 from the infeed / outfeed module 200 to the detection module 300 using the infeed / outfeed robot suction module 5. This process can begin with step 252 of process 250, in which the infeed / outfeed robot 1 can pick up and hold (during movement) the post-printed film 103 via suction using the infeed / outfeed robot suction module 5. In some embodiments, the post-printed film 103 can be located at the film transportation mechanism 1006, so the infeed / outfeed robot suction module 5 can pick up and hold the post-printed film 103 at the film transportation mechanism 1006.

[0205] In some embodiments, the onboarding / offboarding robotic suction cup 102 can create a negative pressure path at multiple locations of the post-printed film 103, thereby allowing the onboarding / offboarding robotic suction cup module 5 and the onboarding / offboarding robot 1 to temporarily hold the post-printed film 103. In some embodiments, the drug units 104 can be disposed on one side of the post-printed film 103, and the onboarding / offboarding robotic suction cup 102 can contact the same side of the post-printed film 103. In some embodiments, the onboarding / offboarding robotic suction cup 102 can create a negative pressure path at locations on the post-printed film 103 where no drug units 104 are deposited.

[0206] In some embodiments, the drug units 104 can be temporarily connected to the post-printed film 103. As a result, the step 252 can cause the onboarding / offboarding robotic suction cup module 5 to pick up both the post-printed film 103 and the drug units 104.

[0207] The onboarding / offboarding robotic suction cup module 5 can transport the post-printed film 103 from the film transport mechanism (e.g., the film transport mechanism 1006 discussed below Figure 9B in step 254 to the staging site 8. Because the onboarding / offboarding robotic suction cup 102 can hold the post-printed film 103 and the drug units 104 at the time of step 254, the post-printed film 103 and the drug units 104 can also be transported to the staging site 8.

[0208] In some embodiments, transporting the post-printed film 103 in step 254 can include moving the onboarding / offboarding robotic suction cup module 5 from the film transport mechanism 1006 to the staging site 8. Those skilled in the art will appreciate that moving a module attached to a robot can include moving both the module and the robot. For example, moving the onboarding / offboarding robotic suction cup module 5 from the film transport mechanism 1006 to the staging site 8 can include moving the onboarding / offboarding robot 1 along a z-plane, moving the onboarding / offboarding robot 1 along an x-plane, a y-plane, or both, and moving (e.g., rotating) the onboarding / offboarding robotic suction cup module 5.

[0209] In some embodiments, transporting the post-printed film 103 in step 254 can include releasing the suction of the post-printed film 103 at the staging site 8. Releasing the suction can include removing the negative pressure created at the onboarding / offboarding robotic suction cup 102. In some embodiments, releasing the suction can cause the onboarding / offboarding robotic suction cup 102 to stop holding the post-printed film 103, and the post-printed film 103 can then be placed at the staging site 8.

[0210] In some embodiments, one or more conditions can have to be met before a step is executed. Exemplary conditions can include, but are not limited to: the on / off loading robot 1 is available and not executing another step, and the on / off loading robot suction cup module 5 is available and not executing another step. As another exemplary condition, in some embodiments, before step 254 is executed, the staging station 8 can need to sense that the post-print film 103, the drug unit 104, or both are not present at the offloading station 10. In some embodiments, when an exemplary condition is not met, the control module can cause the step to be delayed in execution.

[0211] In some embodiments, the order of events can be preprogrammed into software that can be executed by the on / off loading robot 1.

[0212] Exemplary transport of new film

[0213] In some embodiments, the on / off loading module 200 can be configured to provide a new film to the additive manufacturing device. To provide the new film, the on / off loading robot suction cup module 5 can automatically transport the new film from the film library 7 to the staging station 8. In some embodiments, the film transport mechanism can pick up and transport the new film from the staging station 8 to the additive manufacturing device.

[0214] In step 256, the on / off loading robot suction cup 102 of the on / off loading robot suction cup module 5 can be used to pick up and hold (during movement) the new film from the film library 7 via suction. In some embodiments, the on / off loading robot suction cup 102 can create a path of negative pressure at multiple locations of the new film, thereby allowing the on / off loading robot suction cup module 5 and the on / off loading robot 1 to temporarily hold the new film.

[0215] The on / off loading robot suction cup module 5 can also transport the new film from the film library 7 to the film transport mechanism 1006. In some embodiments, transporting the new film in step 256 can include moving the on / off loading robot suction cup module 5 from the film library 7 to the film transport mechanism 1006. Moving a module attached to a robot can include moving both the module and the robot. For example, moving the on / off loading robot suction cup module 5 from the film library 7 to the film transport mechanism 1006 can include moving the on / off loading robot 1 along the z-plane, moving the on / off loading robot 1 along the x-plane, the y-plane, or both, and moving (e.g., rotating) the on / off loading robot suction cup module 5.

[0216] In some embodiments, transporting the new film in step 256 can include releasing a suction of the new film at the film transport mechanism 1006. Releasing the suction can include removing a negative pressure generated at the on / off film robot suction cup 102. In some embodiments, releasing the suction can cause the on / off film robot suction cup 102 to stop holding the new film, and the new film can then be placed at the film transport mechanism 1006.

[0217] In some embodiments, one or more conditions can have to be met before a step is executed. Exemplary conditions can include, but are not limited to, the on / off film robot 1 being available and not executing another step, and the on / off film robot suction cup module 5 being available and not executing another step. As another exemplary condition, in some embodiments, the staging station 8 can need to sense that there is no post-print film 103 and no new film at the staging station 8 before step 254 is executed. As another exemplary condition, in some embodiments, the offloading station 10 can need to sense that there is a new film at the film library 7 before step 256 is executed. As yet another exemplary condition, in some embodiments, the sensor 307 coupled to the film library 7 can need to complete any adjustment to the z-height of one or more new films located at the film library 7 before step 256 is executed. In some embodiments, when an exemplary condition is not met, the control module can cause the step to be delayed in execution.

[0218] In some embodiments, the order of events can be preprogrammed into software that can be executed by the on / off film robot 1.

[0219] Exemplary separation of a drug unit from a post-print film

[0220] In addition to automatically transporting the post-print film 103 and automatically transporting the new film, the on / off film module 200 can be configured to assist in separating the drug unit 104 from the post-print film 103. In some embodiments, the on / off film module 200 can use the on / off film robot gripper module 4 to separate the drug unit 104 from the post-print film 103.

[0221] In some cases, the on / off film robot 1 can need to replace the on / off film robot suction cup module 5 with the on / off film robot gripper module 4 (step 258 of process 250). Replacing the on / off film robot suction cup module 5 with the on / off film robot gripper module 4 can include detaching from the on / off film robot suction cup module 5 and attaching to the on / off film robot gripper module 4.

[0222] Unloading from the loading / unloading robot suction cup module 5 can include moving the loading / unloading robot 1 to a library location 213 and placing the loading / unloading robot suction cup module 5 at the library location 213 using the automated transfer tool 6. In some embodiments, the loading / unloading robot jaw module 4 can be stored at a library location 215 and the loading / unloading robot 1 can have to move to the library location 215 in order to attach to the loading / unloading robot jaw module 4.

[0223] In step 260, the loading / unloading robot 1 of the loading / unloading robot module 200 can cooperate with the inspection robot (e.g., the inspection robot 2 discussed below) of the inspection module 300 to separate the drug unit 104 from the post-print film 103. For step 260, the loading / unloading robot 1 can use the loading / unloading robot jaw module 4 to grip the drug unit 104 and the inspection robot 2 can grip the post-print film 103.

[0224] Figure 3F A flowchart illustrating exemplary operations of a loading / unloading module cooperating with an inspection module to separate a drug unit from a post-print film is illustrated in accordance with some embodiments of the present disclosure.

[0225] Process 260A can be a process illustrating steps taken by the loading / unloading robot 1 to separate the drug unit 104 from the post-print film 103. Process 260B discussed below can be a process illustrating steps taken by the inspection robot (e.g., the inspection robot 2 discussed below) of the inspection module 300 to separate the post-print film 103 from the drug unit 104. In some embodiments, the loading / unloading module 200 can cooperate with the inspection module 300 to separate the drug unit 104 from the film 103. In some embodiments, process 260A can occur simultaneously with process 260B. Figure 4A

[0226] Process 260A can begin with step 262, in which the loading / unloading robot jaw 101 can pick up a drug unit 104 at the unloading station 10. In some embodiments, each loading / unloading robot jaw 101 can be configured to grip one drug unit 104. In some embodiments, the loading / unloading robot jaw 101 can include jaw pieces that, when closed, grip the drug unit 104 and, when open, release the drug unit 104. When closed, the jaw pieces can be closer together to enclose the sides of the drug unit 104. When open (i.e., releasing the drug unit 104), the jaw pieces can be separated so that they no longer enclose the sides of the drug unit 104.

[0227] In step 264, the loading / unloading robot jaw module 4 can be moved toward the inspection robot module (e.g., the inspection robot module 300 discussed below) of the inspection module 300. In some embodiments, the loading / unloading robot 1 can move the loading / unloading robot jaw module 4 to the inspection robot module 300. In some embodiments, the loading / unloading robot 1 can move the loading / unloading robot jaw module 4 to the inspection robot module 300 using the automated transfer tool 6. Figure 4A ​the detection robot module 343) moves. In some embodiments, the infeed / outfeed robot gripper module 4 can move from the staging station 8 to the outfeed station 10. Because the infeed / outfeed robot gripper module 4 can hold the pharmaceutical unit 104 at step 264, the pharmaceutical unit 104 can also move toward the detection robot module 343. Additionally, because the post-print film 103 can be temporarily connected to the pharmaceutical unit 104 at step 264, the post-print film 103 can also move toward the detection robot module 343.

[0228] Those skilled in the art will appreciate that moving a module attached to a robot can include moving both the module and the robot. For example, moving the infeed / outfeed robot gripper module 4 from the outfeed station 10 toward the detection robot module 343 can include moving the infeed / outfeed robot 1 along the x-plane, the y-plane, the z-plane, or both. In some embodiments, the infeed / outfeed robot gripper module 4 can be rotated in step 266 such that the detection robot gripper of the detection robot module 343 (e.g., the detection robot gripper 202 discussed below in connection with step 284) can access the post-print film 103. Figure 4B

[0229] In step 268, the infeed / outfeed robot gripper module 4 and the infeed / outfeed robot gripper 101 can hold the pharmaceutical unit 104. During this step, in some embodiments, the infeed / outfeed robot gripper module 4 can be oriented such that the infeed / outfeed robot gripper 101 extends along the x-plane, similar to that shown in Figure 3D For example, the infeed / outfeed robot gripper 101 can hold the pharmaceutical unit 104 in the air while the detection robot gripper 202 of the detection robot module 343 peels the post-print film 103 (e.g., step 284 discussed below in connection with Figure 4C

[0230] In some embodiments, the infeed / outfeed robot gripper 101 can hold the pharmaceutical unit 104 while the detection robot module 343 moves toward the infeed / outfeed robot gripper module 4 (e.g., step 280 discussed below in connection with Figure 4C In some embodiments, the infeed / outfeed robot gripper 101 can hold the pharmaceutical unit 104 while the detection robot gripper 202 grips the post-print film 103 (e.g., step 282 discussed below in connection with Figure 4C

[0231] After step 268 is complete, the pharmaceutical unit 104 can be separated from the post-print film 103. At this point, in some embodiments, the infeed / outfeed robot gripper 101 can hold the pharmaceutical unit 104 without being temporarily connected to the post-print film 103.

[0232] Referring again to Figure 3E ​​​by first moving the on / off loading robot gripper module 4 to the off loading station 10, the on / off loading robot gripper 101 of the on / off loading robot gripper module 4 can place the pharmaceutical unit 104 downward (step 270). Moving a module attached to a robot can include moving both the module and the robot. For example, moving the on / off loading gripper module 4 to the off loading station 10 can include lowering the on / off loading robot 1 along a z-plane, moving the on / off loading robot 1 along an x-plane, a y-plane, or both, and moving (e.g., rotating) the on / off loading robot gripper module 4.

[0233] Step 270 can also include the on / off loading robot gripper 101 releasing the grip on the pharmaceutical unit 104 at the off loading station 10. As described above, in some embodiments, releasing the grip can include separating the jaw pieces of the on / off loading robot gripper 101 such that the spacing between the jaw pieces is greater than the diameter of the pharmaceutical unit 104.

[0234] Exemplary detection module

[0235] Figure 4A A plan view of an exemplary detection module according to some embodiments of the present disclosure is illustrated. The detection module 300 can be used to detect the pharmaceutical units 104. The detection module 300 can include the detection robot 2, the off loading station 10, the weighing station 11, the waste bin 12, the film recycling bin 13, and the detection robot module 343.

[0236] The detection robot 2 can be a robotic arm including a plurality of beams and one or more connection joints. The detection robot 2 can be capable of moving along a plurality (e.g., six) degrees of freedom. In some embodiments, the one or more connection joints can be located between the beams, and the detection robot 2 can have two ends. The first end can be attached to a table-like surface (as shown), and the second end can be capable of having a module attached thereto. For example, the detection robot module 343 can be capable of being attached to and unattached from the second end of the detection robot 2.

[0237] The detection robot 2 can be configured to receive one or more control signals from a computer system (e.g., one or more computer systems of the control module 600). The control signals can be used to control the movement of the detection robot 2. In some embodiments, the control signals can be used to control the movement of the detection robot module 343. Figure 6

[0238] ​The infeed station 10 can be configured to receive the pharmaceutical units 104. In some embodiments, the infeed station 10 can be configured to receive the pharmaceutical units 104 from the infeed / outfeed module 200, where the pharmaceutical units 104 can be temporarily connected to the post-print film 103 when received. In some embodiments, the infeed station 10 can be configured to receive the pharmaceutical units 104 from the infeed / outfeed module 200, where the pharmaceutical units 104 can have been separated from the post-print film 103 (e.g., step 158 discussed above). In some embodiments, the pharmaceutical units 104 at the infeed station 10 can be configured to hold the pharmaceutical units 104 while a robotic camera tool (discussed below) captures one or more images of the pharmaceutical units 104. In some embodiments, the pharmaceutical units 104 at the infeed station 10 can be configured to hold at least some of the pharmaceutical units in a production batch prior to transporting and weighing the at least some of the pharmaceutical units in the production batch at the weighing station 11.

[0239] In some embodiments, the infeed station 10 can be a dedicated area located in the inspection module 300. In some embodiments, the infeed station 10 can be located at a position where the second end of the infeed / outfeed robot 1 and the second end of the inspection robot 2 can be able to reach the infeed station 10.

[0240] In some embodiments, the infeed station 10 can have physical characteristics (e.g., size, shape, etc.) determined based on the physical characteristics of the pharmaceutical units 104 and the production batch. For example, the infeed station 10 can include a plurality of geometric features (e.g., the geometric features 106 of FIG. 1). For example, the geometric features can be dimples. The pharmaceutical units 104 can be located in the plurality of geometric features 106 while at the infeed station 10. The physical characteristics (such as size and shape) of the plurality of geometric features 106 can be based on the physical characteristics (such as size and shape) of the pharmaceutical units 104. In some embodiments, each pharmaceutical unit 104 can be located in one geometric feature 106. Figure 4F

[0241] In some embodiments, the number of the plurality of geometric features 106 can be greater than or equal to 32. Embodiments of the present disclosure can include any number of geometric features 106, such as 10, 12, 24, 40, etc. In some embodiments, the number of geometric features 106 can be equal to the number of pharmaceutical units 104 in a single production batch.

[0242] ​In some embodiments, the de-stacker station 10 can have a sensor coupled thereto to determine whether an object, such as a post-print film 103 or a drug unit 104, is located at the de-stacker station 10. In some embodiments, the sensor can determine the type of object at the de-stacker station 10 based on a physical characteristic, such as a size, a shape, a weight, an amount of surface contact with a worktable of the de-stacker station 10, and the like. In some embodiments, the sensor can be a proximity sensor. The sensor can indicate and / or trigger the inspection robot 2 to perform certain steps, such as separating a drug unit 104 from a post-print film 103 or inspecting a drug unit 104. In this manner, the inspection robot 2 can operate continuously, thereby increasing the throughput of the inspection module 300.

[0243] The weighing station 11 can include one or more weighing scales to measure the weight of a drug unit 104 located at the weighing station 11. In some embodiments, the weighing resolution of the weighing scales can be 0.1 mg.

[0244] In some embodiments, the number of weighing scales can be greater than or equal to four. In some embodiments, each weighing scale can be configured to measure the weight of one drug unit 104 at a given time. In some embodiments, the number of weighing scales can be equal to the number of inspection robot suction cups (e.g., the inspection robot suction cup 201 discussed below), the number of geometric features 106 of the in-line placement of the de-stacker station 10, or the number of both. Figure 4B

[0245] In some embodiments, the physical characteristics (e.g., size, shape, and the like) of the weighing scales of the weighing station 11 can be determined based on the physical characteristics of the drug units 104. In some embodiments, the one or more weighing scales can include one or more pockets to hold a drug unit 104 whose weight is measured at a given time. In some embodiments, the drug unit 104 held by the pocket can be a set of drug units 104 of a production batch. For example, the pocket can prevent the drug unit 104 from moving before, during, and after the weight measurement. In some embodiments, the weighing station 11 can be located proximate to the de-stacker station 10. For example, the weighing station 11 can be located adjacent to the de-stacker station 10.

[0246] The reject bin 12 can be used to hold non-conforming drug units 104. In some embodiments, the reject bin 12 can be used to temporarily hold non-conforming drug units 104 until they are re-used or recycled. In some embodiments, the reject bin 12 can be located proximate to the weighing station 11. For example, the reject bin 12 can be located adjacent to the weighing station 11.

[0247] ​The membrane recycling bin 13 can be used to hold the one or more post-printing membranes 103 after they have been separated from the drug unit 104. In some embodiments, each post-printing membrane 103 can be stacked within the membrane recycling bin 13 along a different z-height. In some embodiments, the membrane recycling bin 13 can be located near the weighing station 11. For example, the membrane recycling bin 13 can be located adjacent to the weighing station 11 (not shown). In some embodiments, the recycling bin 13 can be located at the bottom of the membrane deformation separation module 700 (not shown). In some embodiments, the membrane recycling bin 13 can be a metal box.

[0248] Figure 4B A plan view of an exemplary detection robot module according to some embodiments of the present disclosure is illustrated. The detection robot module 343 may be attached to the detection robot 2. In some embodiments, the detection robot module 343 may include a detection robot suction cup 201 for picking up the drug unit 104 via suction by creating multiple negative pressure paths. In some embodiments, the detection robot suction cup 201 may be located on a side 343A of the detection robot module 343, as shown.

[0249] In some implementations, the inspection robot suction cups 201 can be operated independently. Independent operation means that each inspection robot suction cup 201 can be controlled independently, such that suction generated by one inspection robot suction cup 201 does not affect the other inspection robot suction cup 201. For example, at a given time, the first inspection robot suction cup 201 may use suction, while the second inspection robot suction cup 201 may not use suction.

[0250] In some embodiments, the number of detection robot suction cups 201 may be equal to or greater than four. Although the figure shows four detection robot suction cups 201, embodiments of this disclosure may include any number of detection robot suction cups 201, such as 2, 3, 5, 6, etc. In some embodiments, the number of detection robot suction cups 201 may be equal to the number of weighing scales at weighing position 11, the number of geometric features arranged in rows at unloading position 10, or both.

[0251] In some embodiments, the spacing between adjacent inspection robot suction cups 201 can be equal to the spacing between adjacent recesses of the weighing scale (at weighing position 11). In some embodiments, the spacing between adjacent inspection robot suction cups 201 can be equal to the spacing between adjacent geometric features 106 at the unloading station 10. In some embodiments, the spacing between adjacent inspection robot suction cups 201 can be equal to the spacing between adjacent recesses in blister packaging. In some embodiments, the spacing between adjacent inspection robot suction cups 201 can be equal to the spacing between adjacent slots in the membrane deformation separation module 700 (e.g., Figure 7Athe spacing between the slots 910 of the gripper 101.

[0252] In some embodiments, the inspection robot module 343 can include inspection robot grippers 202 for gripping the post-print film 103. The inspection robot grippers 202 can grip the ends of the post-print film 103 by gripping multiple locations of the post-print film 103. In some embodiments, the inspection robot grippers 202 can grip the post-print film 103 by bringing their jaws closer to enclose the sides of the post-print film 103 (e.g., as shown in FIG. 2). The inspection robot grippers 202 can also release their grip on the post-print film 103 by bringing their jaws apart and no longer enclosing the sides of the post-print film 103. In some embodiments, the inspection robot grippers 202 can be pneumatic. Figure 4D

[0253] In some embodiments, the characteristics, components, and / or functions of the inspection robot grippers 202 can be the same as those of the infeed / outfeed robot grippers 101 (of the infeed / outfeed module 200). In some embodiments, the inspection robot grippers 202 can be configured such that the spacing between their jaws when closed is less than that of the infeed / outfeed robot grippers 101.

[0254] In some embodiments, the inspection robot grippers 202 can be located on the side 343B of the inspection robot module 343, as shown in FIG. 3. Although this figure illustrates three inspection robot grippers 202, embodiments of the present disclosure can include any number of inspection robot grippers 202, such as 1, 2, 4, 8, 12, 16, etc. In some embodiments, the number of inspection robot grippers 202 can be based on the size of the post-print film 103. For example, the number of inspection robot grippers 202 can be increased when a larger pulling force is needed, such as for larger post-print films 103. Figure 4B

[0255] In some embodiments, the inspection robot module 343 can include an inspection robot camera tool for capturing one or more images of the drug units 104 in a production batch. In some embodiments, the inspection robot camera tool can be configured to capture one or more images of one or more drug units 104 when the one or more drug units are located at the outfeed station 10. In some embodiments, the inspection robot camera tool can be configured to capture multiple images for a single production batch. The inspection robot camera tool can capture multiple images in succession by capturing a set of drug units 104 in each image. In some embodiments, the number of drug units 104 in one image captured by the inspection robot camera tool can be equal to the number of weigh scales of the weighing station 11, the number of geometric features of the outfeed stations 10 of the in-line placement station, the number of inspection robot suction cups 201, or a combination thereof.​​

[0256] The inspection robot camera tool can include a number of components, such as a camera lens 203 (shown), a multi-spectral light 204 (shown), and an image sensor 205 (shown). The camera lens 203 can be positioned closer to the pharmaceutical unit 104 than the multi-spectral light 204 and the image sensor 205. The camera lens 203 can be configured to magnify and / or focus on the pharmaceutical unit 104 while the image sensor 205 captures one or more images. In some embodiments, the multi-spectral light 204 can be configured to illuminate the pharmaceutical unit 104 while the image sensor 205 captures one or more images. In some embodiments, the image sensor 205 can be a CCD image sensor. In some embodiments, the image sensor 205 can be an industrial vision sensor. Figure 4G Figure 4G Figure 4G

[0257] Exemplary operations of the inspection module

[0258] The inspection module 300 can be configured to perform various operations, such as automatically separating the post-print film 103 from the pharmaceutical unit 104, automatically inspecting the pharmaceutical unit 104 by capturing an image, automatically inspecting the pharmaceutical unit 104 by measuring a weight, and automatically transporting the acceptable pharmaceutical units 104 or the unacceptable pharmaceutical units 104 to the blister machine 15 or the waste bin 12, respectively. Each operation will be discussed in turn below.

[0259] Exemplary separation of post-print film from pharmaceutical unit

[0260] As discussed above, the inspection module 300 can operate in conjunction with the infeed / outfeed module 200 to separate the pharmaceutical unit 104 from the post-print film 103. Figure 4C A flowchart illustrating exemplary operations of the inspection module 300 to separate the post-print film 103 from the pharmaceutical unit 104 in accordance with some embodiments of the present disclosure is shown.

[0261] The process 260B can be a process illustrating the steps taken by the inspection robot 2 to separate the post-print film 103 from the pharmaceutical unit 104. The process 260A discussed above can be a process illustrating the steps taken by the infeed / outfeed robot 1 to separate the pharmaceutical unit 104 from the post-print film 103. In some embodiments, the process 260B can occur simultaneously with the process 260A.

[0262] ​​​Process 260B can begin with step 280, in which detection robot 2 can be moved toward the on / off loading robot gripper module 4. Prior to and / or during step 352, the on / off loading robot gripper module 4 and its on / off loading robot gripper 101 can be holding a drug unit 104 with the on / off loading robot gripper 101 extending along the x-plane (see, e.g., Figure 3D ). In some embodiments, step 280 (moving detection robot module 343) can occur simultaneously with step 268 (drug unit 140 is held by on / off loading robot gripper module 4).

[0263] Those skilled in the art will appreciate that moving a module attached to a robot can include moving both the module and the robot. For example, moving detection robot module 343 toward on / off loading robot gripper module 4 can include moving or lowering detection robot 2 along the z-plane, moving detection robot 2 along the x-plane and / or y-plane, rotating detection robot module 343, or a combination thereof.

[0264] In step 282, detection robot gripper 202 can grip the post-print film 103. In some embodiments, detection robot gripper 202 can grip an end (e.g., a top end) of the post-print film 103, as shown in Figure 4D In some embodiments, detection robot gripper 202 can be a jaw that, when closed, grips the post-print film 103 and, when open, releases the film 103. When closed, the jaw can be closer together to enclose the film 103. When open (i.e., to release the post-print film 103), the jaw can be spread apart so that they no longer enclose the sides of the post-print film 103.

[0265] In step 284, detection robot gripper 202, detection robot module 343, and detection robot 2 can strip the post-print film 103. Stripping can include a pulling force that originates at the top end of the post-print film 103 (i.e., closest to detection robot module 343) and propagates to the bottom end of the post-print film 103 (i.e., farthest from detection robot module 343). In some embodiments, stripping can occur by moving the top end, as gripped by detection robot gripper 202, along the y-plane and z-plane. In some embodiments, pulling can occur while the drug unit 104 is held by the on / off loading gripper 101 (e.g., step 280).

[0266] After step 284 is complete, the post-print film 103 can be separated from the drug unit 104. Detection robot gripper 202 can hold the post-print film without the drug unit 104 being temporarily connected to the post-print film 103.

[0267] Referring to Figure 3EIn step 272, the inspection robot gripper 202 can process the post-printing film 103 by transporting it to the film recycling bin 13. Transporting the post-printing film 103 to the film recycling bin 13 may include: moving the inspection robot module 343 to the film recycling bin 13 (e.g., by moving the inspection robot 2 along the x-plane, y-plane, z-plane or any combination thereof; and moving (e.g., rotating) the inspection robot module 343).

[0268] In some embodiments, transporting the separated post-printing film 103 may include releasing the gripping of the post-printing film 103 at the film recycling box 13. Releasing the gripping may include separating the grippers of the inspection robot gripper 202 such that the spacing between the grippers is greater than the thickness of the post-printing film 103.

[0269] After the detection robot gripper 202 processes and separates the post-printing film 103, the detection module 300 can continue to detect the drug unit 104 in process 350.

[0270] Exemplary detection of drug units by capturing images

[0271] After the drug unit 104 separates from the post-printing membrane 103, the drug unit 104 can be prepared for detection. The detection module 300 can be configured to detect one or more characteristics of the drug unit 104. An exemplary type of characterization may include capturing one or more images of the drug unit 104 using a detection camera tool.

[0272] Figure 4E A flowchart illustrating exemplary operation of a detection module according to some embodiments of the present disclosure for detecting and automatically transporting a drug unit is provided. The detection process may begin in process 350 by detecting the drug unit 104 based on images captured using a detection camera tool.

[0273] In step 352 of process 350, the detection robot 2 can use a detection camera tool to capture images of a set of drug units 104. Figure 4F The flowchart shows the details of process 352.

[0274] In step 354 of process 352, the inspection robot 2 can move to the unloading station 10, where the drug unit 104 can be positioned. The module attached to the robot can be moved, including both the moving module and the robot. For example, moving the inspection robot module 343 to the unloading station 10 can include moving the inspection robot 2 along the x-plane, y-plane, z-plane, or a combination thereof. Figure 4G As shown, the detection robot module 343 can also rotate in step 356 so that the imaged drug unit 104 becomes visible to the image sensor 205 (e.g., in the line of sight).

[0275] At step 358, the image sensor 205 can capture an image of a set of drug units 104. In some embodiments, the inspection robotic camera tool can be configured to capture multiple images for a single production batch. The inspection robotic camera tool can capture multiple images in succession by capturing a set of drug units 104 in each image. The process 352 can be repeated for each set of drug units 104. In some embodiments, images of drug units 104 for a production batch can be captured one at a time. For example, as shown, the inspection camera tool can capture a first image of a first set of drug units 104A. Later (e.g., at a second execution of the process 352), the inspection camera tool can capture a second image of a second set of drug units 104H. Figure 4G

[0276] For different images, the inspection robotic module 343 can be positioned at different x-stations. For example, an x-station of the inspection robotic module 343 for capturing a first image of a first set of drug units 104A can be different than an x-station of the inspection robotic module 343 for capturing a second image of a second set of drug units 104H.

[0277] In some embodiments, a set of drug units 104 can include less than all of the drug units 104 in a production batch. For example, a number of drug units 104 in a set of drug units 104 can be equal to a number of inspection robotic chucks, a number of geometric features in the rowed drop-off station 10, a number of weighing scales at the weighing station 11, and the like. In some embodiments, a set of drug units 104 can include four drug units 104.

[0278] In some embodiments, the inspection robotic camera tool can capture some (e.g., all) of the multiple images for a single production batch before determining whether the drug units 104 are acceptable and before transporting the drug units 104 to the blister machine 15 or the reject bin 12. In some embodiments, the image sensor 205 or the control module of the inspection robotic camera tool can use the images to perform image data processing to determine whether the drug units 104 are acceptable. In some embodiments, the image information can be communicated to the control module for processing, storage, linking to the drug units 104, or a combination thereof.

[0279] Example inspection of drug units by measuring weight

[0280] Another example type of characterization can include measuring a weight of a drug unit 104 using the weighing station 11, such as in the process 360 of Figure 4E

[0281] ​​In process 360, in some embodiments, the detection module 300 can transport a set of drug units 104 to a weighing station 11, so that the weighing station can measure the weight of the set of drug units 104. Figure 4H The flowchart shows the details of process 360.

[0282] In step 362 of process 360, the inspection robot 2 may be moved to the unloading station 10. Moving the module attached to the robot may include both the moving module and the robot. For example, moving the inspection robot module 343 to the unloading station 10 may include moving the inspection robot 2 along the x-plane, y-plane, z-plane, or a combination thereof.

[0283] The inspection robot module 343 can be rotated in step 364 so that the inspection robot suction cup 201 can reach the drug unit 104. In some embodiments, rotating the inspection robot module 343 in step 364 can make the side 343A face the unloading station 10.

[0284] In step 366, the inspection robot suction cup 201 can be used to pick up a group of drug units 104 from a production batch. In some embodiments, the inspection robot suction cup 201 can create a negative pressure path to generate suction on the group of drug units 104. In some embodiments, each inspection robot suction cup 201 can be configured to pick up one drug unit 104.

[0285] In some embodiments, a group of drug units 104 may include fewer than all drug units 104 in a single production batch. For example, the number of drug units 104 in a group of drug units 104 may be equal to the number of detection robot suction cups, the number of geometric features in the row of unloading stations 10, the number of weighing scales 11 at the weighing position, etc. In some embodiments, a group of drug units 104 may be equal to four drug units 104.

[0286] In step 368, the detection robot module 343 can be moved to the weighing position 11. This step may include, for example, moving the detection robot module 343 and / or the detection robot 2 to the weighing position 11 by moving the detection robot 2 along the x-plane, y-plane, z-plane, or a combination thereof. Because the detection robot suction cup 201 can hold a set of drug units 104 during step 368, the set of drug units 104 can be moved to the weighing position 11.

[0287] In step 370, the inspection robotic puck 201 can release the suction on the set of drug units 104, thereby placing them at the weighing station 11. Releasing the suction can include removing the negative pressure generated at the inspection robotic puck 201. In some embodiments, releasing the suction can cause the inspection robotic puck 201 to stop holding the set of drug units 104, which can then be placed at the weighing station 11.

[0288] The weighing station 11 can measure the weight of the drug units 104 (step 372). To determine whether the drug units 104 are qualified, the weight of the drug units 104 can be used to determine a characteristic of the drug units. In some embodiments, the weighing station 11 can take individual measurements from each weighing scale to determine the weight of the respective drug unit 104. In some embodiments, the weighing station can take a single measurement from all weighing scales to determine the weight of the respective set of drug units 104. For example, when the weighing station 11 includes four weighing scales, the single measurement can represent the weight of the four drug units 104.

[0289] In some embodiments, the weight information can be transmitted to the control module for processing, storage, linking to the drug units 104, or a combination thereof.

[0290] The inspection module 300 can be configured to measure the weight of the drug units 104 using multiple measurements. The weighing station 11 can take multiple weight measurements in succession by measuring a set of drug units 104 for each measurement. Each set can include at least some, but not all, of the drug units 104. The process 360 can be repeated for each set of drug units. In some embodiments, the weight of the drug units 104 for a production batch can be captured one by one. For example, the weighing station 11 can measure a first set of drug units 104A in a first measurement, and then later (e.g., at a second execution of the process 360) can measure a second set of drug units 104H in a second measurement.

[0291] The inspection robotic module 343 can be configured to move to different x-positions to pick up different rows of drug units 104 for each weight measurement. For example, the x-position of the inspection robotic module 343 to pick up a first set of drug units 104A in step 362 can be different from the x-position of the inspection robotic module 343 to pick up a second set of drug units 104H.

[0292] Example processing of qualified and unqualified drug units

[0293] After the inspection camera tool captures images of the drug units 104 (in step 352) and the weighing station measures the weight of the drug units 104 (in step 360), the control module can determine whether the drug units are qualified (step 374 of process 350, as shown in FIG. 3B). The control module can determine whether the drug units are qualified based on the weight of the drug units 104, the images of the drug units 104, or a combination thereof.Figure 4E as shown).

[0294] If the drug units are not qualified, the process 376 can handle the unqualified drug units 104 by automatically transporting the unqualified drug units 104 to the reject bin 12. Figure 4E A flowchart illustrating exemplary operations of automatically transporting unqualified drug units to a reject bin, in accordance with some embodiments, is illustrated. Figure 4I A flowchart illustrating exemplary operations of automatically transporting unqualified drug units to a reject bin, in accordance with some embodiments, is illustrated.

[0295] From step 378, the inspection robot module 2 can move to the weighing station 11. Moving the inspection robot 2 to the weighing station 11 can include moving along the x-plane, y-plane, z-plane, or a combination thereof. In step 380, the inspection robot module 343 can be rotated such that the inspection robot suction cups 201 are accessible to the set of drug units 104 at the weighing station 11. In some embodiments, rotating the inspection robot module 343 for step 380 can cause the side 343A (on which the inspection robot suction cups 201 can be located) to face the pockets of the weighing scales at the weighing station 11.

[0296] In step 382, the inspection robot suction cups 201 can pick up the set of drug units 104 at the weighing station 11. In some embodiments, the inspection robot suction cups 201 can generate a negative pressure path to create suction on the set of drug units 104 at the weighing station 11. In some embodiments, each inspection robot suction cup 201 can be configured to pick up one drug unit 104.

[0297] In some embodiments, only the inspection robot suction cups 201 corresponding to the locations of the unqualified drug units 104 at the weighing station 11 can be used for picking up. For example, if the unqualified drug units 104 are positioned at the second and third weighing scales of the weighing station 11, only the second and third inspection robot suction cups 201 can be used to pick up the corresponding qualified drug units 104. In this case, the first and fourth inspection robot suction cups 201 do not generate a negative pressure path and do not pick up the first and fourth drug units 104. In some embodiments, the drug units 104 that are not picked up can be considered as qualified drug units 104 and can be handled accordingly, as described below.

[0298] In step 384, the inspection robot 2 can move to the reject bin 12. This step can include moving the inspection robot module 343 and / or the inspection robot 2 to the reject bin 12, for example, by moving the inspection robot 2 along the X-plane, Y-plane, Z-plane, or a combination thereof. Because the inspection robot suction cups 201 can hold the unqualified drug units 104 from the weighing station 11, the set of drug units 104 can be moved to the reject bin 12.

[0299] In step 386, the detection robot suction cup 201 can release suction on the unqualified drug units 104, thereby placing them at the waste bin 12. Releasing suction can include removing the negative pressure generated at the detection robot suction cup 201. In some embodiments, releasing suction can cause the detection robot suction cup 201 to stop holding the unqualified drug units 104.

[0300] In some embodiments, only the detection robot suction cup 201 holding the unqualified drug units can release suction at the waste bin 12. For example, the detection module 300 can transport the unqualified drug units to the waste bin 12 before transporting the qualified drug units to the blister machine 15. In some embodiments, the detection robot suction cup 201 can hold both the qualified and unqualified drug units 104, and only the detection robot suction cup 201 holding the unqualified drug units can release suction to place the unqualified drug units at the waste bin 12. In some embodiments, the drug units 104 that are not released can be considered as qualified drug units and can be processed accordingly, as described below.

[0301] If the drug units are qualified, then in process 388, the detection module 300 can automatically transport the qualified drug units 104 to the blister machine 15. Figure 4E Figure 4J A flowchart illustrating exemplary operations of automatically transporting qualified drug units to a blister machine, in accordance with some embodiments, is shown in FIG. 4.

[0302] From step 390, the detection robot 2 can move to the weighing station 11. Moving the detection robot 2 to the weighing station 11 can include moving along the x-plane, y-plane, z-plane, or a combination thereof. In step 392, the detection robot module 343 can rotate such that the detection robot suction cup 201 can access the set of drug units 104 at the weighing station 11. In some embodiments, rotating the detection robot module 343 to perform step 392 can cause the side 343A at which the detection robot suction cup 201 can be located to face the pockets of the weighing scale at the weighing station 11.

[0303] In step 394, the detection robot suction cup 201 can pick up the set of drug units 104 at the weighing station 11. In some embodiments, the detection robot suction cup 201 can generate a negative pressure path to create suction on the set of drug units 104 at the weighing station 11. In some embodiments, each detection robot suction cup 201 can be configured to pick up one drug unit 104.

[0304] ​In some embodiments, only the detection robot suction cups 201 corresponding to the locations of the qualified drug units 104 at the weighing stations 11 can be used for picking. For example, if the qualified drug units 104 are positioned at the first and fourth weighing scales at the weighing stations 11, only the first and fourth detection robot suction cups 201 can be used to pick the corresponding qualified drug units 104. In this case, the second and third detection robot suction cups 201 do not create a negative pressure path, and do not pick the second and third drug units 104. In some embodiments, the drug units 104 that are not picked can be considered unqualified drug units 104, and can be handled accordingly, as described above.

[0305] At step 396, the detection robot 2 can move to the blister machine 15. This step can include moving the detection robot module 343 and / or the detection robot 2 to the blister machine 15 by, for example, moving the detection robot 2 along the x-plane, the y-plane, the z-plane, or a combination thereof. Because the detection robot suction cups 201 can hold the qualified drug units 104 from the weighing stations 11, the set of drug units 104 can be moved to the blister machine 15.

[0306] At step 398, the detection robot suction cups 201 can release the suction on the qualified drug units 104, thereby placing the qualified drug units at the blister machine 15. Releasing the suction can include removing the negative pressure created at the detection robot suction cups 201. In some embodiments, releasing the suction can cause the detection robot suction cups 201 to stop holding the qualified drug units 104.

[0307] In some embodiments, only the detection robot suction cups 201 holding the qualified drug units can release the suction at the blister machine 15. For example, the detection module 300 can transport the qualified drug units to the blister machine 15 before transporting the unqualified drug units to the waste bin 12. In some embodiments, the detection robot suction cups 201 can hold both the qualified and unqualified drug units 104, and only those detection robot suction cups 201 holding the qualified drug units can release the suction to place the qualified drug units at the blister machine 15. In some embodiments, the drug units 104 that are not released can be considered unqualified drug units, and can be handled accordingly, as described above.

[0308] In some embodiments, not all of the set of drug units 104 located at the weighing station 11 row can be acceptable. The unacceptable drug units 104 can be transported to a different location than the acceptable drug units 104 (e.g., the waste bin 12). In some embodiments, the inspection robotic gripper 201 can pick up all of the set of drug units 104 at the weighing station 11 (e.g., at process 376), regardless of whether the drug units 104 are acceptable or not. The inspection robotic gripper 201 can then automatically transport the drug units 104 to the waste bin 12 and release the unacceptable drug units at the waste bin (e.g., at step 386). The inspection robotic gripper 201 can automatically transport the drug units 104 to the blister machine 15 and release the acceptable drug units at the blister machine (e.g., at step 398). In this case, steps 390, 392, and 394 can be omitted, for example.

[0309] In some embodiments, the inspection unit 300 can measure and transport a set of drug units 104, and then continue measuring and transporting another set of drug units. For example, the inspection unit 300 can capture a first image and a first weight of a first set of drug units (e.g., drug units 104A) and automatically transport the first set of drug units 104A to the blister machine 15 or the waste bin 17, and then capture a second image and a second weight of a second set of drug units (e.g., drug units 104H) and automatically transport the second set. In this way, as Figure 4E shown, steps 352, 360, 374, 376, and 388 can be repeated for each set of drug units 104.

[0310] Exemplary packaging module

[0311] In some embodiments, the packaging module 500 can include a blister machine 15, as Figure 2A shown. The blister machine 15 can be configured to package acceptable drug units 104 in blister packaging. In some embodiments, the blister packaging can include a sheet having a plurality of geometric features, such as dimples. The plurality of geometric features can be configured to hold one or more drug units 104.

[0312] In some embodiments, the geometric feature of the blister packaging can be a recess formed in the sheet. The sheet having the geometric feature can include any type of material configured to hold and protect the drug units 104. Exemplary materials can include, but are not limited to, plastic, aluminum, and the like.

[0313] The blister pack can be configured to use a protective layer to protect the drug unit 104 from external factors such as humidity, contamination, temperature fluctuations, and ultraviolet radiation. An exemplary protective layer may include aluminum. In some embodiments, the protective layer may be a flat, non-rigid sheet that can be punctured, peeled off, or both.

[0314] The blister packaging machine 15 can be configured to hold the blister pack while it is filled with qualified pharmaceutical units 104. The blister packaging machine 15 can also be configured to seal the filled blister pack. In some embodiments, the blister machine 15 may use a cold aluminum sealing process to seal the blister pack.

[0315] After the blister packer 15 completes the sealing and packaging of the blister packs, the blister packing station 420 can receive the blister packs. The blister packs can remain at the blister packing station 420 until they are automatically transported to the packaging module 500.

[0316] Exemplary operation of a blister pack machine

[0317] In some embodiments, the blister pack machine 15 can be operated using a cold aluminum stamping process to form geometric features, such as recesses, in the aluminum strip. Recesses can be formed by punching them into the aluminum strip.

[0318] In some implementations, in Figure 5C In step 452 of process 450, the inspection robot suction cup 201 can place the qualified drug unit 104 into the recesses of the aluminum strip. Once all the recesses in a portion of the aluminum strip are filled, the blister pack machine 15 can seal the aluminum strip. In some embodiments, the blister pack machine can separate the aluminum strip into multiple blister packages. The blister pack machine 15 can move the sealed blister packages to the blister packing station 420.

[0319] In some embodiments, sealing the aluminum strip may include using a cold aluminum sealing process, wherein an aluminum protective layer may be placed on top of the geometrically defined aluminum strip. When the protective layer is placed on top of the geometrically defined feature, the edges of the protective layer may contact the aluminum strip. The aluminum strip and the protective layer may be bonded together using processes such as crimping or sealing with an adhesive (e.g., pressure-sensitive adhesive).

[0320] Figure 5AA plan view of an example packaging module according to some embodiments of the present disclosure is illustrated. The packaging module 500 can be used to assemble and seal a cartridge (e.g., a paperboard cartridge). The packaging module 500 can also be used previously to automatically transport cartridges with suction. In some embodiments, the packaging module 500 can be used to automatically transport blister packs. In some embodiments, the packaging module 500 can be used to label blister packs, cartridges, or both. The packaging module 500 includes a packaging robot 3, a labeling station 14, a cartridge library 17, a cartridge loading station 18, a palletizing station 16, and a packaging robot module 543. In some embodiments, the packaging module 500 can include the blister machine 15 described above.

[0321] The packaging robot 3 can be a robotic arm including a plurality of links and one or more connecting joints. The packaging robot 3 can be capable of movement along a plurality (e.g., six) degrees of freedom. In some embodiments, the one or more connecting joints can be located between the links, and the packaging robot 3 can have two ends. The first end can be attached to a table-like surface (as shown), and the second end can be capable of having a tool attached thereto. For example, the packaging robot module 543 can be attached to the second end of the packaging robot 3.

[0322] The packaging robot 3 can be configured to receive one or more control signals from a computer system (e.g., one or more computer systems 600 of a control module). The control signals can be used to control movement of the packaging robot 3. In some embodiments, the control signals can be used to control movement of the packaging robot module 543.

[0323] The labeling station 14 can be configured to add one or more labels to a blister pack, a cartridge, or both. In some embodiments, the labeling station 14 can include a laser that engraves or prints the one or more labels on the blister pack and / or cartridge. In some embodiments, the laser labeling station 14 can be a hybrid laser marker.

[0324] The labels can include or link to information such as the type of drug unit 104; the date of manufacture; the production lot number associated with the corresponding continuous production process; the inspection properties of the drug unit (e.g., appearance, such as color, weight, diameter, defects, etc.); the production lot conditions (e.g., production temperature, pressure, time, etc.); and the like. For example, this information can be conveyed in the form of a label of a two-dimensional (e.g., bar code, QR code, alphanumeric characters) type. The label, such as a QR code, can be a unique identifier of the drug unit 104, making it traceable to manufacturing information, such as material feeding stages, printing stages, and inspection stages.

[0325] In some embodiments, the marking station 14 can include a marking pocket (not shown) configured to receive a blister pack or a cartridge. The packaging robot (of the packaging robot 3) can automatically transport the blister pack or the cartridge to the marking station 14 by placing the blister pack or the cartridge at the marking pocket. The marking pocket can be coupled to an actuator (e.g., a motor, a pneumatic device, etc.). The actuator can automatically move the marking pocket holding the blister pack or the cartridge from a first station to a second station. The first station can be located at a position where the blister pack or the cartridge is accessible to the packaging robot (of the packaging robot 3). The second station can be located at a position where the blister pack or the cartridge is accessible to the laser, such as below the laser. Once the blister pack or the cartridge is below the laser (i.e., at the second station), the laser can add the label, and then the marking pocket can automatically move the blister pack or the cartridge to the first station.

[0326] The cartridge library 17 can hold cartridges before the cartridges are assembled. In some embodiments, the cartridge library 17 can hold one or more flat cartridges. The cartridges can be cartridges that hold blister packs and protect the blister packs from environmental exposure. In some embodiments, the flat cartridges can be arranged vertically along different y-stations within the cartridge library 17. In some embodiments, the cartridges in the cartridge library 17 can be semi-finished cartridges.

[0327] The cartridge library 17 can include or can be attached with sensors and actuators, such as position sensing devices (not shown). The sensors can be configured to ensure that the front surface of the foremost cartridge in the cartridge library 17 is at a predetermined y-station. For example, when the packaging robot 3 removes the foremost (first) cartridge from the cartridge library 17, the front surface of the next (second) cartridge can be at a different y-station. The sensors can sense the change in the y-station, and the actuators can move the second cartridge (or the stack of cartridges including the second cartridge) to ensure that the front surface of the second cartridge is at the predetermined y-station. In this way, the packaging robot 3 can not need to adjust the y-station needed for each pick of a flat cartridge, thereby increasing the throughput of the packaging module 300.

[0328] The boxing station 18 can be used to assemble a medicine box. In some embodiments, the boxing station 18 can be configured to hold a medicine box while one or more blister packs are placed in the medicine box. In some embodiments, the boxing station 18 can also be configured to hold a medicine box and at least partially seal one or more ends of the medicine box. In some embodiments, the boxing station 18 can include one or more movable push cylinders configured to fold one or more flaps of a medicine box for sealing. In some embodiments, the boxing station 18 can include three push cylinders. A first push cylinder can be configured to fold a first flap of a medicine box. A second push cylinder can be configured to fold a second flap, and a third push cylinder can be configured to fold a third flap. In some embodiments, the movable push cylinders can fold the flaps of a medicine box by pressing the flaps of the medicine box.

[0329] In some embodiments, the boxing station 18 can include a plurality of surfaces configured to hold sides of a medicine box for assembly. The plurality of surfaces of the boxing station 18 can be arranged to form a cavity, where the shape and size of the cavity can be similar to a medicine box once assembled. In some embodiments, the medicine box can be a cube or an orthotope having four sides and two ends, a top end and a bottom end. Each end can include flaps to be folded and sealed. The four sides can be sides along the length of the medicine box. In some embodiments, the boxing station 18 can be configured to rotate the medicine box to allow the push cylinders and the press blocks 302 to fold and seal the top end and the bottom end of the medicine box.

[0330] The stacking station 16 can be configured to hold a stack of medicine boxes after the medicine boxes are packaged and sealed. In some embodiments, the stacking station 16 can be an acrylic box. In some embodiments, the stacking station 16 can be a cube with its front side exposed. The stacking station 16 can be coupled to a sensor and an actuator (e.g., a motor, a pneumatic device, etc.). The sensor can be configured to sense the height of the stack of medicine boxes. The actuator can be used to adjust the height of the stack of medicine boxes in the stacking station 16. The sensor and the actuator can be configured to ensure that the top surface of the top-most medicine box in the stacking station 16 is at a predetermined height. For example, when the packaging robot 3 adds a medicine box to the stacking station 16, the top-most (first) medicine box in the stacking station 16 can be at a z-height that is higher than the predetermined z-height. The sensor can sense this height change, and the actuator can adjust (e.g., lower) the height of the stack of medicine boxes in the stacking station 16 to ensure that there is empty space for the next medicine box to be placed in the stack of medicine boxes. In this way, the packaging robot 3 can not need to adjust the z-height for each placement of a medicine box in the stack of medicine boxes, thereby increasing the throughput of the packaging module 500.

[0331] In some embodiments, the packaged and sealed cartridges can be cartridges that include one or more blister packs. In some embodiments, all of the ends of the sealed cartridges can be sealed. In some embodiments, one or more sensors (not shown) can be coupled to the palletizing station 16. The one or more sensors can be configured to determine whether a packaged and sealed cartridge is present in the palletizing station 16.

[0332] The packaging robot module 543 can be attached to the packaging robot 3. Figure 5B A side view of an exemplary packaging robot module according to some embodiments of the present disclosure is illustrated.

[0333] The packaging robot module 543 can include a packaging robot suction cup 303 for picking up and holding a blister pack or a cartridge, a press block 302 for pressing a flap of a cartridge, and a dispenser 301 for dispensing glue on a cartridge. In some embodiments, the packaging robot suction cup 303 can be located on a side 543A of the packaging robot module 543, the press block 302 can be located on a second side 543B, and the dispenser 301 can be located on a third side, as shown.

[0334] The packaging robot suction cup 303 can be configured to create a plurality of negative pressure paths that allow the packaging robot suction cup 303 to pick up a blister pack or a cartridge via suction. Although this figure illustrates four packaging robot suction cups 303, embodiments of the present disclosure can include any number, such as 1, 2, 5, 6, etc. In some embodiments, the number of packaging robot suction cups 303 can be based on the size and / or weight of the blister pack, the cartridge, or both. Additionally or alternatively, the relative arrangement of the packaging robot suction cups 303 can be based on the shape of the blister pack, the cartridge, or both.

[0335] The press block 302 can be configured to press a flap of a cartridge. In some embodiments, the press block 302 can be a metal block. In some embodiments, the flap pressed by the press block 302 can be a flap that seals an end of a cartridge. For example, the press block 302 can be used to press a fourth flap of a cartridge to close a bottom end of the cartridge.

[0336] The dispenser 301 can be configured to dispense an adhesive, such as glue. In some embodiments, the dispenser 301 can be configured to dispense glue on a flap of a cartridge. For example, the dispenser 301 can dispense glue on a third flap of a cartridge. After the glue is dispensed, a fourth flap can be folded on top of the dispensed glue to seal the cartridge.

[0337] Exemplary operation of a packaging module

[0338] The packaging module 500 can be configured to perform various operations, such as automatically transporting and labeling blister packs, automatically assembling medication cartridges, automatically transporting and labeling medication cartridges, and automatically filling and transporting a palletizing station. Each of these operations will be discussed in turn below.

[0339] Example Transporting and Labeling of Blister Packs

[0340] After the aluminum strips with medication units 104 are sealed and separated into blister packs, the blister packs can be transported and labeled through the labeling station 14. In some embodiments, the packaging module 500 can automatically transport the blister packs using the packaging robot suction cup 303 attached to the packaging robot module 543 of the packaging robot 3. Figure 5C A flowchart illustrating example operations of a packaging process according to some embodiments of the present disclosure is shown.

[0341] After the blister pack is sealed by the blister machine 15 (step 452), the packaging robot 3 can automatically transport the blister pack to the labeling station 14 using the packaging robot suction cup 303 in process 454.

[0342] Process 454 can begin with step 456, as shown. Figure 5D In step 456, the packaging robot 3 can be moved to the blister pack station 420. Moving the packaging robot 3 to the blister pack station 420 can include moving along the x-plane, y-plane, z-plane, or a combination thereof. In step 458, the packaging robot module 543 can be rotated so that the packaging robot suction cup 303 is accessible to the blister pack. In some embodiments, rotating the packaging robot module 543 to step 458 can cause the packaging robot suction cup 303 to face the blister pack.

[0343] In step 460, the packaging robot suction cup 303 can pick up the blister pack at the blister pack station 420. In some embodiments, the packaging robot suction cup 303 can create a negative pressure path to create suction at multiple locations of the blister pack.

[0344] In step 462, the packaging robot 3 can move the packaging robot module 543 to the labeling station 14. This step can include moving the packaging robot 3, for example, along the x-plane, y-plane, z-plane, or a combination thereof. Because the packaging robot suction cup 303 can hold the blister pack, movement of the packaging robot module 543 can cause the blister pack to also move to the labeling station 14. In step 464, the packaging robot suction cup 303 can release the suction on the blister pack, thereby placing the blister pack at the labeling station 14. In some embodiments, the packaging robot suction cup 303 can place the blister pack at a labeling pocket of the labeling station 14.

[0345] Referring again toFigure 5C The marking station 14 can add one or more labels to the blister pack (step 466). The added label can be, for example, a barcode, a QR code, or alphanumeric characters.

[0346] After the blister pack is marked, the packaging module 500 can automatically transport the blister pack from the marking station 14 to the boxing station 18, where the blister pack can be placed in a pillbox (process 468). Figure 5E A flowchart illustrating exemplary operations of automatically transporting a blister pack from a marking station to a boxing station according to some embodiments of the present disclosure is illustrated. In step 470 of process 468, the packaging robot 3 can move to the marking station 14. Moving the packaging robot 3 to the marking station 14 can include moving along the x-plane, the y-plane, the z-plane, or a combination thereof. In step 472, the packaging robot module 543 can be rotated such that the packaging robot suction cup 303 is accessible to the blister pack. In some embodiments, rotating the packaging robot module 543 can cause the packaging robot suction cup 303 to face the blister pack.

[0347] In step 474, the packaging robot suction cup 303 can pick up the blister pack at the marking station 14. In some embodiments, the packaging robot suction cup 303 can create a negative pressure path to create suction at multiple locations of the blister pack to pick up the blister pack.

[0348] In step 476, the packaging robot 3 can move the packaging robot module 543 to the boxing station 18. This step can include, for example, moving the packaging robot 3 along the x-plane, the y-plane, the z-plane, or a combination thereof. Because the packaging robot suction cup 303 can hold the blister pack, the movement of the packaging robot module 543 can cause the blister pack to also move to the boxing station 18.

[0349] In step 478, the packaging robot suction cup 303 can release the suction on the blister pack such that the blister pack is inserted into an end of a pillbox held by the boxing station 18. In some embodiments, the blister pack can be inserted into a top end of the pillbox. For example, the top end of the pillbox can be facing upwards when the pillbox is held by the cavity of the boxing station 18. The packaging robot module 543 can angle the blister pack to be upright or near upright such that it slides into the top end of the pillbox when released in step 478.

[0350] Exemplary assembly of a pillbox

[0351] Another operation of the packaging module 500 can be the assembly of a pillbox. To assemble a pillbox, the packaging module 500 can have to transport a flat pillbox from the box library 17 to the boxing station 18. Figure 5FA flowchart illustrating exemplary operations of the packaging module 500 automatically transporting a flat carton from the carton library 17 to the carton loading station 18 according to some embodiments of the present disclosure is shown.

[0352] To transport the flat carton, the packaging robot 3 can move to the carton library 17 (step 542 of process 540). In some embodiments, the packaging robot 3 can have to move the packaging robot 3 along the x-plane, y-plane, z-plane, or a combination thereof. The packaging robot module 543 can have to rotate so that the packaging robot suction cup 303 is accessible to the carton (step 544). The rotation of the packaging robot module 543 can be such that the packaging robot suction cup 303 faces a particular side of the carton (e.g., the front side).

[0353] The packaging robot suction cup 303 can pick up the carton at the carton library 17 via suction (step 546). The packaging robot 3 can move the packaging robot module 543 holding the carton to the carton loading station 18 by moving along the x-plane, y-plane, z-plane, or a combination thereof (step 548). The packaging robot suction cup 303 can release the suction on the carton, thereby causing the carton to be placed at the carton loading station 18 (step 550).

[0354] To assemble the carton, it can have to be unfolded. Figure 5G A flowchart illustrating exemplary operations of unfolding a carton according to some embodiments of the present disclosure is shown.

[0355] For example, before the process 552 begins, the carton loading station 18 can hold an unfolded carton in the cavity of the carton loading station 18. In some embodiments, the carton loading station 18 can hold the back side of the carton (step 554), and the front side (e.g., along the length of the carton) can face outward from the carton loading station 18. In steps 556 and 558, the packaging robot 3 can move to the carton loading station 18 and rotate the packaging robot module 543 so that its packaging robot suction cup 303 faces the front side of the carton.

[0356] In step 560, the packaging robot suction cup 303 can pull on the front side of the carton with suction, thereby causing the carton to unfold. After the carton is unfolded, the carton can be three-dimensional, with the top and bottom ends of its flaps yet to be folded. In some embodiments, each end of the carton can have four flaps.

[0357] At step 562, the boxing station 18 can fold and seal the flaps of the bottom end of the medicine box. The first push cylinder of the boxing station 18 can be used to press and fold the first flap. In some embodiments, the first flap can be on the left side of the medicine box when facing the front side of the medicine box, and pressing the first flap can cause it to fold towards the right side of the medicine box. The boxing station 18 can fold the second flap by using the second push cylinder that presses the second flap. In some embodiments, the second flap can be on the right side of the medicine box when facing the front side of the medicine box, and pressing the second flap can cause it to fold towards the left side of the medicine box. The boxing station 18 can also fold the third flap by using the third push cylinder that presses the third flap. In some embodiments, the third flap can be on the top of the medicine box when facing the front side of the medicine box, and pressing the third flap can cause it to fold downwards. In some embodiments, after folding the first, second, and third flaps, the third flap can be on top of the first and second flaps.

[0358] At step 564, the packaging robot module 543 can rotate to utilize its glue dispenser 301. The rotation can cause the glue dispenser 301 to be accessible to the third flap of the medicine box. At step 566, the glue dispenser 301 can dispense glue. In some embodiments, the glue can be dispensed on the third flap of the medicine box.

[0359] At step 568, the packaging robot module 543 can rotate to utilize its press block 302 such that the press block 302 is accessible to the fourth flap of the medicine box. In some embodiments, at step 568, the fourth flap of the medicine box can be unfolded, and the press block 302 can be facing the fourth flap.

[0360] At step 570, the packaging robot module 543 and the packaging robot 3 can move the press block 302 towards the fourth flap of the medicine box, thereby causing the fourth flap to fold towards the third flap of the medicine box. After the press block 302 folds the fourth flap of the medicine box, the fourth flap can be on top of the third flap with a layer of glue between the third and fourth flaps. In some embodiments, the third push cylinder of the boxing station 18 can press down on the fourth flap, thereby causing it to adhere to the third flap.

[0361] After sealing the bottom end of the medicine box, the boxing station 18 can rotate the medicine box, thereby exposing the top end of the medicine box. After the rotation, the top end of the medicine box can be open and can not be sealed. As described above, the packaging module 500 can place one or more blister packs in the medicine box in process 468.

[0362] After placing the one or more blister packs in the medicine box, the packaging module 500 can seal the medicine box and complete the packaging using the press block 302 and the glue dispenser 301 (Figure 5C The process 480 of moving the packaging robot module 543 to the cartoning station 18 is illustrated.

[0363] Figure 5H The process 480 of moving the packaging robot module 543 to the cartoning station 18 is illustrated (step 482). The packaging robot module 543 can rotate such that the third flap is accessible to the glue dispenser 301 (step 484).

[0364] The glue dispenser 301 can dispense glue on the third flap of the medicine cassette (step 486). The packaging robot module 543 can rotate such that the fourth flap is accessible to the press block 302 (step 488). The press block 302 can press the fourth flap such that it is folded onto the third flap of the medicine cassette (step 490). The third push cylinder of the cartoning station 18 can press down on the flaps of the medicine cassette, thereby sealing the medicine cassette (step 492).

[0365] Exemplary transport and marking of a medicine cassette

[0366] Another operation of the packaging module 500 can be to automatically transport the medicine cassette to the marking station 14. Figure 5I A flowchart of an exemplary operation of the packaging module 500 automatically transporting the medicine cassette to the marking station 14 is illustrated, according to some embodiments of the present disclosure.

[0367] The packaging robot 3 can move to the cartoning station 18 (step 574 of the process 572). In some embodiments, the packaging robot module 543 can have to move the packaging robot 3 along the x-plane, y-plane, z-plane, or a combination thereof. The packaging robot module 543 can have to rotate such that the packaging robot suction cup 303 is accessible to the medicine cassette (step 576). The rotation of the packaging robot module 543 can be such that the packaging robot suction cup 303 faces the front side of the medicine cassette.

[0368] The packaging robot suction cup 303 can pick up the medicine cassette at the cartoning station via suction (step 578). The packaging robot 3 can move the packaging robot module 543 holding the medicine cassette to the marking station 14 by moving along the x-plane, y-plane, z-plane, or a combination thereof (step 580). The packaging robot suction cup 303 can release the suction on the medicine cassette, thereby causing the medicine cassette to be placed at the marking station 14 (step 582).

[0369] Once the medicine cassette is at the marking station 14, the marking station 14 can mark the medicine cassette. In some embodiments, the marking station 14 can use a laser or ink to add (e.g., engrave, print, etc.) one or more labels to the medicine cassette.

[0370] After the medicine cassette is marked, the packaging module 500 can automatically transport the medicine cassette from the marking station 14 to the palletizing station 16 in the process 584. Figure 5JA flowchart of process 584 is shown, which begins at step 586.

[0371] In step 586, the packaging robot 3 can move to the marking position 14. The packaging robot module 543 can rotate so that its packaging robot suction cup 303 is accessible (e.g., facing) the medicine box at the marking position 14 (step 588).

[0372] In step 590, the packaging robot module 543 and the packaging robot suction cup 303 can pick up the medicine box at the marking position 14. In step 592, the packaging robot module 543 can move the medicine box to the palletizing station 16. At the palletizing station 16, the robot module 543 can place the medicine box there by releasing the suction from the packaging robot suction cup 303 (step 594).

[0373] Exemplary filling and transport at a palletizing station

[0374] In some implementations, the palletizing station 16 can be configured to hold multiple medicine boxes. As described above, in Figure 5I In step 578, the packaging robot module 543 can place the medicine boxes at the palletizing station 16. The packaging robot module 543 can continue placing the packaged and sealed medicine boxes into the palletizing station 16 until the palletizing station 16 is full. After placing each medicine box into an empty slot in the palletizing station 16, the palletizing station 16 can make room for another empty slot until there are no more empty slots. Making room for another empty slot can include lowering the height of the medicine box pallet. Lowering the height of the medicine box pallet ensures that the packaging robot 3 does not need to adjust its z-height when transporting each medicine box.

[0375] Once palletizing station 16 is filled with medicine boxes, the palletizing station transport mechanism (not shown) can automatically transport the filled palletizing station 16 out of the unloading and packaging device 100. Then, the palletizing station transport mechanism can automatically transport the empty station 16 to the unloading and packaging device 100.

[0376] Exemplary control module

[0377] The control module can be configured to control the feeding and packaging device 100, the feeding / unloading module 200, the detection module 300, the packaging module 500, and the film deformation separation module (e.g., discussed below). Figure 7A The membrane deformation separation module 700 and the smart material deformation separation module (discussed below) Figure 8A The intelligent material deformation separation module 800 or a combination thereof. In some embodiments, the control module may also be configured to control... Figure 1 and Figure 9Ba plurality of print positions 1000. The control module can include one or more computer systems. In some embodiments, the control module can enable the blanking and packaging system to operate in the form of a continuous and automated process of the overall additive manufacturing printing system.

[0378] Figure 6 A block diagram of an exemplary control module according to some embodiments of the present disclosure is illustrated. The control module 600 can be a host computer connected to a network. The control module 600 can include a client computer or a server. As shown, the control module 600 can include any suitable type of microprocessor-based device, such as a personal computer, a workstation, an embedded system, a programmable logic control (PLC), a field programmable gate array (FPGA), a server, or a handheld computer system (i.e., a portable electronic device, such as a phone, a tablet, etc.). The control module 600 can include, for example, one or more processors 610, one or more input devices 620, one or more output devices 630, memory 640, software 650, and one or more communication devices 660. The one or more input devices 620 and the one or more output devices 630 can generally correspond to those described below and can be connected or integrated with the control module 600. Figure 6

[0379] The one or more input devices 620 can include any suitable device that provides input, such as a touchscreen, a keyboard or keypad, a mouse, a voice recognition device, etc. The one or more output devices 630 can include any suitable device that provides output, such as a touchscreen, a haptic device, a speaker, etc.

[0380] The memory 640 can include any suitable device that provides storage, such as electrical, magnetic, or optical storage including a random access memory (RAM), a cache memory, a hard disk drive, or a removable storage disk.

[0381] The one or more communication devices 660 can include any suitable device that enables communication over a network, such as a network interface chip or device. The components of the control module 600 can be connected in any suitable manner, such as via a physical bus or wirelessly.

[0382] ​Software 650 that can be stored in memory 640 and executed by processor 610 can include, for example, a program embodying the functionality of the present disclosure (e.g., controlling operation of the modules and components thereof as described above). Software 650 can also be stored and / or transported within any non-transitory computer-readable storage medium for use by or in connection with an instruction execution system, apparatus, or device, such as those described above, which can fetch instructions from the instruction execution system, apparatus, or device and execute the instructions, in the context of the present disclosure, a computer-readable storage medium can be any medium, such as memory 640, that can contain or store programs for use by or in connection with an instruction execution system, apparatus, or device.

[0383] Software 650 can also be transmitted or transported within any transport medium for use by or in connection with an instruction execution system, apparatus, or device, such as those described above. Non-limiting exemplary instruction execution systems, apparatus, or devices can fetch instructions associated with software from the instruction execution system, apparatus, or device and execute the instructions. In the context of the present disclosure, a transport medium can include any medium that can carry or transfer programs for use by or in connection with an instruction execution system, apparatus, or device. The transport readable medium can include, but is not limited to, an electronic, magnetic, optical, electromagnetic, or infrared propagated wireless medium.

[0384] Control module 600 can be connected to a network, which can be any suitable type of interconnected communication system. The network can implement any suitable communication protocol and can be secured by any suitable security protocol. The network can include network links of any suitable arrangement that can implement transmission and reception of network signals, such as wireless network connections, T1 or T3 lines, cable networks, DSL, or telephone lines.

[0385] Control module 600 can implement any operating system suitable for operation on the network. Software 650 can be written in any suitable programming language, such as C, C++, Java, Python, etc. In some embodiments, for example, application software embodying the functionality of the present disclosure can be deployed in different configurations, such as in a client / server arrangement, or through a web browser as a web-based application or web service.

[0386] Exemplary operations of the control module

[0387] The control module can be configured to control the operation of the devices. In some embodiments, the control module can control the parallel and independent operation of each device. Independent operation can mean that the operation of one device can not affect the operation of another device. Independent operation can be beneficial in situations requiring high throughput, for example, but not limited to. In some cases, each module or device can not have the same throughput. As such, when the modules or devices are not operated independently, the overall throughput of the load and system can be limited by the lowest throughput module or device.

[0388] For example, the material dropping and packaging system can include a first material dropping and packaging device 100 and a second material dropping and packaging device 100. The control module can send one or more first control signals to the first material dropping and packaging device 100 to control its operation. The control module can also send one or more second control signals to the second material dropping and packaging device 100 to control its operation. In some embodiments, the control module can cause the first material dropping and packaging device 100 to operate. At the same time, the control module can cause the second material dropping and packaging device 100 to not operate (e.g., due to routine maintenance). In some embodiments, the control module can cause the first material dropping and packaging device 100 to not operate and the second material dropping and packaging device 100 to operate. In some embodiments, the control module can cause both the first material dropping and packaging device 100 and the second material dropping and packaging device 100 to operate.

[0389] The control module can also be configured to control the operation of the modules within a given material dropping and packaging device 100. The control module can control the parallel and independent operation of each module. For example, the control signals can send one or more first control signals to the packaging module 500 to control its operation on a first production batch. At the same time, the control module can send one or more second control signals to the material loading / dropping module 200 to control its operation on a second production batch.

[0390] The control module can also be configured to control the continuous and automated transport within the modules. In some embodiments, the control module can be configured to control the continuous and automated transfer between the modules.

[0391] The control module can also be configured to control the storage of information and / or link the information to a remote computer or server of the drug units 104. Exemplary information can include, but is not limited to, characterization information, production batch information, 3D printing process information, etc.

[0392] In some embodiments, the control module can be configured to record information related to the continuous manufacturing process. The information can include, but is not limited to, control signals, movements, activities, and states of the devices, robots, modules, components, machines, films, drug units, or any combination thereof. In some embodiments, the recorded information can be linked to the corresponding one or more drug units, as described above.

[0393] Exemplary film deformation separation module

[0394] In some embodiments, the material dropping and packaging system can include a film deformation separation module 700. For example, the film deformation separation module 700 can be located proximate to the material feeding / dropping module 200 and the detection module 300.

[0395] Figures 7A-7B Plan and cross-sectional views of an exemplary film deformation separation module 700 according to some embodiments of the present disclosure are respectively illustrated. The film deformation separation module 700 can be used to separate the drug units 104 from the post-printed film 103. In some embodiments, the film deformation separation module 700 can separate the drug units 104 from the post-printed film by deforming the post-printed film 103. The film deformation separation module 700 can include a driving friction wheel 906 and a driven friction wheel 907, one or more pneumatic actuators 903, an electric actuator 904 (e.g., a motor), a support frame 908, a material dropping plate 905, and a guide slot 909.

[0396] In some embodiments, the electric actuator 904 can be used to rotate the driving friction wheel 906. The driving friction wheel 906 can cooperate with the driven friction wheel 907 to move the post-printed film 103 along the x-plane. In some embodiments, the driving friction wheel 906 and the driven friction wheel 907 can move the post-printed film 103 along the x-plane toward the guide slot 909. In some embodiments, the driving friction wheel 906 and the driven friction wheel 907 can contact and enclose the post-printed film 103, such as Figure 7B For example, the driving friction wheel 906 and the driven friction wheel 907 can rotate as portions of the post-printed film 103 move between them, with one rotating in a clockwise direction and the other rotating in a counterclockwise direction.

[0397] The one or more pneumatic actuators 903 can be used to move the support frame 908 along the z-direction (e.g., upward or downward). The downward movement of the support frame 908 can be used to press down on the post-printed film 103.

[0398] The blanking plate 905 and the guide slot 909 can be configured to create a non-flat profile by bending and deforming the post-print film 103. As described in more detail below, the bending and deforming caused by the blanking plate 905 and the guide slot 909 causes the drug units 104 to separate from the post-print film 103. In some embodiments, the blanking plate 905 can include a plurality of slots 910 configured to receive the drug units 104 after the drug units are separated. In some embodiments, the guide slot 909 can be configured to receive the post-print film 103 after the post-print film is separated.

[0399] Example operation of a film deformation separation module

[0400] In cases where the blanking and packaging apparatus 100 includes the film deformation separation module 700, the infeed / blanking module 200 can automatically transport the post-print film 103 from the staging position 8 to the film deformation separation module 700. Automatically transporting the post-print film 103 from the staging position 8 to the film deformation separation module 700 can be similar to (and / or) step 254 of the method 250, in which the infeed / blanking robot 1 and the infeed / blanking robot suction module 5 move to the film deformation separation module 700 instead of the blanking station 10. Figure 3E

[0401] Figure 7C A flowchart illustrating an example operation of a film deformation separation module according to some embodiments is shown. The process 750 can begin with step 752, in which an end of the post-print film 103 can be fed into the support frame 908.

[0402] In step 754, the electric actuator 904 can rotate the drive friction wheel 906. The drive friction wheel 906 can cooperate with the driven friction wheels 907 to move the post-print film 103 (step 756). In some embodiments, the drive friction wheel 906 can rotate clockwise while one or more driven friction wheels 907 can rotate counterclockwise. This rotation can move the end of the post-print film 103 that was fed into the support frame 908 along the x-plane toward the guide slot 909. The end of the post-print film 103 that was fed into the support frame 908 can hit the guide slot 909, which can cause the post-print film 103 to bend (step 758).

[0403] Meanwhile, in step 760, the blanking plate 905 can deform the post-print film 103 by applying light pressure to certain locations of the post-print film 103. The locations of the light pressure can be outside of the locations where the drug units 104 are located on the post-print film 103. During steps 758 and 760, the drive friction wheel 906 and the driven friction wheels 907 can continue to move the post-print film 103 along the x-plane. Steps 758 and 760 can cause the drug units 104 to separate from the post-print film 103.

[0404] ​In some embodiments, the post-print film 103 can be caused to be ejected from the bottom of the film deformation and separation module 700 after being separated (step 762). In some embodiments, the post-print film 103 can be caused to be automatically transported to the film recycling bin 13 after being separated (step 764). In some embodiments, the film recycling bin 13 can be located at the bottom of the film deformation and separation module 700 and can capture the post-print film 103 as it is ejected from the film deformation and separation module 700.

[0405] In some embodiments, the drug unit 104 can be caused to be advanced through the plurality of slots 910 after being separated (step 766). The step 760 and the step 764 can occur simultaneously.

[0406] In some embodiments, the infeed / outfeed robot gripper 101 of the infeed / outfeed module 200 can be used to automatically transport the drug unit 104 to the outfeed station 10 (step 768).

[0407] Exemplary smart material deformation and separation module

[0408] In some embodiments, the outfeed and packaging system can include a smart material deformation and separation module 800. For example, the smart material deformation and separation module 800 can be located proximate to the infeed / outfeed module 200 and the detection module 300.

[0409] Figure 8A A cross-sectional view of an exemplary smart material deformation and separation module according to some embodiments of the present disclosure is illustrated. The smart material deformation and separation module 800 can be used to separate the drug unit 104 from the post-print film 103 by deforming the smart material 801 coupled to the post-print film 103. The smart material deformation and separation module 800 can include the smart material 801, a circuit (not shown), and a pallet 802.

[0410] The smart material 801 can be a material that is capable of being deformed. In some embodiments, the smart material 801 can be a material that is capable of being dynamically deformed. For example, the smart material 801 can be a piezoelectric material that is capable of changing its shape (e.g., being stretched) in response to one or more signals (e.g., current signals) received from the circuit.

[0411] As shown, the smart material 801 can have at least two ends: a left end 804A and a right end 804B. The smart material 801 can also have a region 804C between the ends. In some embodiments, the deformation can include the smart material 801 stretching along the x-plane (e.g., the length of the smart material 801 in the x-plane can increase). In some embodiments, the deformation can include the smart material 801 bending at its left end 804A and its right end 804B (e.g., the z-positions of the left end 804A and the right end 804B can be different than the z-position of the region 804C). The deformation of the smart material 801 can cause the post-print film 103 to deform, as discussed in more detail below.

[0412] In some embodiments, the platen 802 can be any medium that supports the smart material 801.

[0413] Example operation of a smart material deformation and separation module

[0414] In cases where the material drop and packaging apparatus 100 includes the smart material deformation and separation module 800, the material infeed / drop module 200 can automatically transport the post-print film 103 from the staging position 8 to the smart material deformation and separation module 800. Automatically transporting the post-print film 103 from the staging position 8 to the smart material deformation and separation module 800 can be similar to (the) step 254, where the material infeed / drop robot 1 and the material infeed / drop robot suction module 5 move to the smart material deformation and separation module 800 instead of the material drop station 10. Figure 3E

[0415] Figure 8B A flowchart illustrating an example operation of a smart material deformation and separation module according to some embodiments of the present disclosure is illustrated. The process 850 can begin with step 852, where a post-print film 103 having a drug unit 104 temporarily connected thereto can be placed on top of a smart material 801 and a platen 802. In some embodiments, the post-print film 103 can be temporarily connected to the smart material 801 such that the post-print film 103 follows the movement of the smart material 801. One non-limiting example method for temporarily connecting the post-print film 103 to the smart material 801 can be to add a paste or adhesive substance between the post-print film 103 and the smart material 801. Another non-limiting example method for temporarily connecting the post-print film 103 to the smart material 801 can be to use suction.

[0416] ​One or more signals can be applied to the smart material 801 (step 854). In some embodiments, the smart material 801 can be a material that deforms in response to the applied one or more signals (step 856). In some embodiments, the deformation can include the smart material 801 stretching along the x-plane. For example, the stretching along the x-plane can increase the distance between the left end 804A and the right end 804B.

[0417] In some embodiments, the deformation can include the smart material 801 bending at its ends 804A and 804B. The bending at its ends 804A and 804B can cause the ends 804A and 804B to have a different z-height than the region 804C.

[0418] In step 858, the deformation of the smart material 801 can cause the post-print film 103 to deform accordingly. This deformation of the post-print film 103 can cause the drug units 104 to separate from the post-print film by “ejection.” That is, due to the tensile or bending forces along the x-plane, y-plane, and / or z-plane, the deformation can cause the drug units 104 to temporarily move in the z-plane. In some embodiments, the ejection of the drug units 104 can be due to a mismatch between the deformation of the drug units 104 (i.e., no deformation) and the deformation of the post-print film 103 (i.e., at least some deformation). In some embodiments, after the drug units 104 are ejected, the drug units 104 can move back to the post-print film 103 and can remain on top of it without being temporarily connected thereto (step 860).

[0419] In some embodiments, the infeed / outfeed robot gripper 101 can be used to automatically transport the drug units 104 to the outfeed station 10 (step 862).

[0420] After the drug units 104 have been transported to the outfeed station 10, the detached post-print film 103 can remain on the smart material 801 and the pallet 802 (e.g., on top of it). In step 864, the post-print film 103 can be automatically transported to the film recycling bin 13.

[0421] Example additive manufacturing system

[0422] Figure 9A A view of an example additive manufacturing system 900 is illustrated in accordance with some embodiments of the present disclosure. The additive manufacturing system 900 can include a material supply module 1002 for transporting a set of printing materials to a flow-splitting module 1004. The flow-splitting module 1004 can include a flow-splitting plate having branched channels (not shown) configured to split a single stream of printing materials (e.g., supplied by the material supply module 1002) into multiple streams.

[0423] In some embodiments, the splitting module 1004 can split a single stream into two streams, which can be split into four streams. The four streams can be split into eight streams, and the eight streams can be split into 16 streams. In some embodiments, the 16 streams can be split into 32 streams, and so on. In some embodiments, the splitting module 1004 can split a single stream directly into two streams, three streams, five streams,... or any number of streams. In some embodiments, for example, the splitting module 1004 can split a stream into three streams, which can be split into nine streams, which can be split into 27 streams, and so on.

[0424] In some embodiments, the plurality of streams can be dispensed through a plurality of nozzles (not shown) to print a pharmaceutical unit (e.g., a tablet, a caplet, a print, etc.) on the film 103. The film 103 can be located on top of the print platform 1010.

[0425] The additive manufacturing system 900 can include one or more additive manufacturing controllers to control the plurality of nozzles to dispense the plurality of streams based on a plurality of nozzle-specific parameters.

[0426] Figure 9B A top view of an exemplary layout of a multi-station 3D printing station for additive manufacturing of pharmaceutical units according to some embodiments of the present disclosure is illustrated. The multi-station printing system 1000 can include a plurality of printing stations 900A, 900B, 900C, and 900D. As shown, the plurality of printing stations 900 can be arranged in a linear fashion.

[0427] In FIG. 10B, each of the printing stations 900 includes a set of nozzles (e.g., 32 nozzles) that can be configured to dispense a plurality of streams of printing material on a film 103 to print a production batch of pharmaceutical units 104 (e.g., a batch of tablets).

[0428] In some embodiments, each of the printing stations 900 can be configured to move the film 103 along the x-axis, the y-axis, the z-axis, or a combination thereof. In some embodiments, the additive manufacturing controllers of the printing stations 900 are different from each other, which can be a way of independently controlling the printing stations 900 (e.g., via a control module including one or more additive manufacturing controllers).

[0429] The multi-station printing system 1000 includes a film transport mechanism 1006. The film transport mechanism 1006 can be configured to travel along the lanes 1004A and 1004B. The film transport mechanism 1006 can be configured to operate with the printing stations 900 to move a post-print film 103 from one printing station (e.g., printing station 900A) onto one of the two ends of the film transport mechanism (as shown by arrows 1008A and 1008B), transport the film 103 along either lane (as shown by arrows 1012A and 1012B), and move the film 103 onto another printing station 900. In some embodiments, the operations of the printing stations 900 and the film transport mechanism can be coordinated to maximize manufacturing speed and minimize idle time of the printing stations 900.

[0430] The plurality of printing stations 900 in the multi-station printing system 1000 can be arranged in other layouts. In some embodiments, the plurality of printing stations 900 can be arranged around a circle or a square. In some embodiments, the printing station transport mechanism can include one or more lanes 1004 in the shape of a circle or a square, such that it can transport a post-print film 103 from one printing station 900 to another printing station. In some embodiments, the film transport mechanism includes one or more grippers and / or robots to pick up a post-print film 103 from one printing station (e.g., printing station 900A) and move the post-print film 103 to another printing station (e.g., printing station 900B).

[0431] Example operations of an additive manufacturing system

[0432] Referring again to Figure 3E , the additive manufacturing system operates by having the printing station 300 receive a new film from the film library 7 (step 256). The printing station 900 prints a drug unit 104 on the new film (step 274). The new film on which the printed drug unit 104 is deposited can be referred to as a post-print film 103. The post-print film 103 can be located at an end station after printing (step 276). In some embodiments, the film transport mechanism can transport the post-print film 103 from the end station to a transit station, such that the process 250 can proceed with step 252 described above.

[0433] While the disclosed examples have been fully described in connection with the accompanying drawings, various changes and modifications will become apparent to those skilled in the art. Such changes and modifications should be understood as included within the scope of the disclosed examples as defined by the appended claims.

Claims

1. A continuous production system for infeed and packaging of pharmaceutical units from an additive manufacturing system, the continuous production system comprising: an infeed / outfeed module for receiving the pharmaceutical units from the additive manufacturing system, wherein the pharmaceutical units are deposited on a post-print film when received from the additive manufacturing system; an inspection module for inspecting the pharmaceutical units; and a control module for controlling the infeed / outfeed module and the inspection module, the control causing the infeed / outfeed module and the inspection module to separate the pharmaceutical units from the post-print film.

2. The system of claim 1, wherein, the infeed / outfeed module comprises: an infeed / outfeed robot suction cup module attachable to and detachable from an infeed / outfeed robot by an automatic tool changer.

3. The system of claim 2, wherein, the infeed / outfeed robot suction cup module comprises an infeed / outfeed robot suction cup for picking up the post-print film using suction.

4. The system of claim 3, wherein, the infeed / outfeed robot suction cup is for holding a new film using suction.

5. The system of claim 1, wherein, the infeed / outfeed module comprises: an infeed / outfeed robot gripper module attachable to and detachable from an infeed / outfeed robot by an automatic tool changer.

6. The system of claim 5, wherein, the infeed / outfeed robot gripper module comprises an infeed / outfeed robot gripper for gripping the pharmaceutical units.

7. The system of any one of claims 1 to 6, wherein, the infeed / outfeed module comprises: a film magazine for holding one or more new films.

8. The system of claim 7, wherein, the infeed / outfeed module comprises: a sensor for sensing a height of the one or more new films in the film magazine; and a linear actuator for adjusting the height of the one or more new films in the film magazine.

9. The system of any one of claims 1 to 6, wherein, the infeed / outfeed module comprises: a staging station for receiving the pharmaceutical units deposited on the post-print film from the additive manufacturing system.

10. The system of any one of claims 1 to 6, wherein, the inspection module comprises: an inspection robot module attached to an inspection robot.

11. The system of claim 10, wherein, the inspection robot module comprises an inspection robot suction cup for holding a set of the pharmaceutical units using suction.

12. The system of claim 10, wherein, the inspection robot module comprises an inspection robot gripper for gripping the post-print film.

13. The system of claim 10, wherein, the inspection robot module comprises an inspection robot camera tool for capturing one or more images of a set of the pharmaceutical units.

14. The system of any one of claims 1 to 6, wherein, the inspection module comprises: an infeed station for receiving the pharmaceutical units deposited on the post-print film from the infeed / outfeed module.

15. The system of claim 14, wherein, the infeed station comprises a plurality of geometric features, wherein the pharmaceutical units are configured to be located in the geometric features.

16. The system of any one of claims 1 to 6, wherein, the inspection module comprises: a weighing station comprising one or more weighing scales for weighing a set of the pharmaceutical units, The one or more weigh scales include one or more pockets for holding the set of pharmaceutical units.

17. The system of claim 16, wherein, The spacing between adjacent detection robot suction cups of the detection module is equal to the spacing between adjacent pockets of the one or more weigh scales.

18. The system of any one of claims 1 to 6, wherein, The detection module includes: A reject bin for holding non-conforming pharmaceutical units.

19. The system of any one of claims 1 to 6, wherein, The detection module includes: A film recycling bin for holding post-printing film after the post-printing film is separated from the pharmaceutical units.

20. The system of any one of claims 1 to 6, further comprising: A packaging module for marking, packaging, or both.

21. The system of claim 20, wherein, The packaging module includes a blister machine for packaging conforming pharmaceutical units into blister packs.

22. The system of claim 21, wherein, The packaging module includes a blister pack station for receiving blister packs after the conforming pharmaceutical units are sealed into the blister packs.

23. The system of claim 20, wherein, The packaging module includes a packaging robot module attached to a packaging robot.

24. The system of claim 23, wherein, The packaging robot module includes packaging robot suction cups for holding blister packs, medicine boxes, or both using suction.

25. The system of claim 23, wherein, The packaging robot module includes: A press block for pressing a flap of a medicine box; and A glue dispenser for dispensing glue on a medicine box.

26. The system of claim 23, wherein, The packaging module includes a marking station for marking blister packs, medicine boxes, or both.

27. The system of claim 23, wherein, The packaging module includes a boxing station for assembling medicine boxes, wherein the boxing station is for holding a medicine box while one or more blister packs are placed in the medicine box.

28. The system of claim 23, wherein, The packaging module includes a palletizing station for holding medicine boxes after the medicine boxes are sealed.

29. The system of claim 23, wherein, The packaging module includes a box library for holding medicine boxes before the medicine boxes are assembled.

30. The system of claim 20, wherein, The control module is configured to control operation of the feeding / discharging module, the detection module, a packaging module, or a combination thereof.

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