Buffering systems and methods in tablet packaging and related systems

Abstract

A system comprises an automatic dispensing and packaging system for producing a string of pouches; a further system to receive the string of pouches; and a dynamic buffering system to receive the string of pouches from the automatic dispensing and packaging system at the input side and output the string of pouches to the further system at an output side. The dynamic buffering system is configured to accommodate different numbers of pouches in the string of pouches according to the needs of the automatic dispensing and packaging system and the further system.

Description

[0001] BUFFERING SYSTEMS AND METHODS IN TABLET PACKAGING AND RELATED SYSTEMS

[0002] BACKGROUND

[0003] The disclosure relates to methods, a computer program product and systems for running efficient production processes or operations related to tablet dispensing and packaging devices and related systems, such as inspection systems.

[0004] An example of such a production process and system can be found in US 2014 / 0366489 Al, the contents of which are hereby incorporated by reference. The device and methods disclosed are for dispensing solid substances (e.g., tablets or medicaments) for medical use. Such an example device is depicted in Fig. 1. The device 1 is provided with a great number of feeder units 20, also known as ‘cannisters’, distributed in a radial grid about a rotation axis in a feeder section 2. Each feeder unit holds an amount of solid substances specific to that respective feeder unit. Hence, together, the feeder units can dispense a wide variety of solid substances. The device is further provided with a collection frame 3 that is rotatable about the rotation axis below the array of feeder positions. The collection frame is provided with a series of collection trays 30 for collecting solid substances dispensed from any of the feeder units 20 in the array of feeder positions. The device further comprises a packing unit 4 arranged in a stationary position below the collection frame 3 for packing the solid substances received from the collection trays 30. The collection frame 3 is rotated about the rotation axis such that each collection tray 30 passes along each of the feeder units 20 in the array of feeder positions before arriving at the packing unit 4. The packaging unit forms pouches Pl, P2, P3,..Pn for receiving the solid substances M, fills and seals the pouches after receiving the solid substances, and then collects the pouches on a reel 60 at collection station 6. The reel can then be taken to an inspection station to ensure that the pouches have received the correct solid substances and there are no errors (e.g., broken or missing solid substances, pouch defects, etc.). The device further includes a control unit 8 (with memory 9) which is able to send and receive data and control operations of various system. SUMMARY

[0005] Automated dispensing and packaging devices, such as that found in US 2014 / 0366489 Al, can efficiently and continuously run production operations: dispensing, collecting and packing solid substances into pouches as long as the feeder units are reliably dispensing said solid substances and various systems are working as intended.

[0006] Separate inspections machines are used to inspect the pouches, and then rejected any pouches which did not appear correct. This is typically about 4-5% of pouches, which then required a visual inspection for a final determination.

[0007] Because the automated dispensing and packaging devices and inspection systems operated non-synchronously, the prior art dispensing and packaging devices and inspection machines were typically operated separately. The automated dispensing and packaging devices operates to continuously output pouches (in a step-wise fashion as each pouch is formed), and the inspection machine typically only operates intermittently, starting and stopping the receiving of pouches (but continuously receiving pouches when started), and typically has a higher throughput capacity than the automated dispensing and packaging devices. Because of this non-synchronous operations, rolls of pouches were made at the automated dispensing and packaging device and only later taken for inspection at the inspection machine. The current methods and devices allow for direct connection of the automated dispensing and packaging device and an inspection machine (or other system) that operate non-synchronously by providing buffering systems and methods, thereby allowing for a direct connection between two non-synchronous systems and inspection shortly after the pouches are formed (if the second system is an inspection system). This can result in faster inspection of pouches (less time between production and inspection), an overall more efficient system and process, and in some cases earlier discovery (and possible intervention) of causes of pouch defects.

[0008] According to a first aspect, a dynamic buffering system for buffering a string of pouches produced in an automatic dispensing and packaging system comprises a plurality of upper rollers; and a plurality of lower rollers. The plurality of upper rollers and / or the plurality of lower rollers is moveable such that the buffering system can be expanded or contracted to hold more or fewer pouches in the string of pouches; and the string of pouches connects around the plurality of upper rollers and lower rollers in an alternating fashion from an input side to an output side. The plurality of upper rollers can be displaced (e.g., vertically) from the plurality of lower rollers to accommodate the expanding or contracting. Such a buffering system allows for buffering the pouches being produced by an automatic dispensing and packaging system before the pouches are fed into another system (e.g., an inspection system). The ability of the lower and / or upper rollers to move to expand or contract allows for easily and automatically buffering more or fewer pouches in the string depending on system needs at the time. Such a buffering system then allows for connecting an automatic dispensing and packaging system with another system which operates non-synchronously, for example, the automatic dispensing and packaging system producing pouches in a continuous but step-wise manner with another system which operates intermittently and / or at a different speed. This can result in an overall more efficient system to produce and inspect pouches.

[0009] According to an embodiment, the system further comprises a frame to which the plurality of upper rollers and the plurality of lower rollers connect. The plurality of upper rollers and / or the plurality of lower rollers is moveable along the frame to allow for the expanding or contracting of the buffering system. Moving along a frame can allow for easy movement of the plurality of upper rollers and / or the plurality of lower rollers for the expanding and / or contracting. If the plurality of lower rollers is moveable, movement along the frame can allow for simple movement under the weight of gravity to automatically adjust the size according to the buffering needs at any particular time.

[0010] According to an embodiment, the plurality of lower rollers is moveable. Optionally the lower rollers are weighted, connected to a spring, and / or driven. If driven, this can include being pushed or pulled down using a motor (e.g., constant torque motor), proportionally controlled cylinder and / or other control mechanism. Such weights, motor, spring or other drive mechanism can be in the rollers themselves or connected to a frame to which the rollers are connected. By making the lower rollers moveable (e.g., along a frame), the system can work under the forces of gravity and the string of pouches in the buffering system, allowing for buffering more pouches by lower rollers moving downwards or fewer pouches by lower rollers moving upwards. Upper rollers would be stationary, allowing lower rollers to adjust as necessary to buffering needs at any time. Weighting and / or driving the rollers (or frame the rollers are on) could help ensure that the rollers move as desired and keep tension in the string of pouches, particularly if connected to the lower rollers when forces in the system are very light, as can be the case in a string of pouches with medicaments or tablets.

[0011] According to an embodiment, the plurality of upper rollers extend from an upper frame; and the plurality of lower rollers extend from a lower frame. Optionally, each of the upper and lower frame could be connected to a frame along which at least one of the upper and lower frame is moveable. The connections between the frame and the upper / lower frame can be static (non-moving) or a connection that is moveable along the frame (e.g., rolling or sliding track connection). Typically, the upper frame would have a static connection to the frame, with the lower frame having a movable connection, though this could differ in differing systems. Additionally, the static connection could also be moveable to adjust manually to different working positions. Connecting the upper and / or lower rollers to an upper and lower frame, respectively, ensures that the rollers remain and move together as needed for dynamic buffering. It could also allow for easier and quicker maintenance and / or replacement, allowing for the upper or lower frame with rollers to simply be replaced as a group, minimizing any downtime in system for repair or replacement. In some embodiments, there could be sensors and / or alarms to provide an alert when a moveable set of rollers and / or frame is moving close to maximum allowable movements (e.g., lower frame is very close to the base). This can help to ensure that moveable frames stay withing buffering system limits for proper operations. Optionally, such sensors and / or alarms could start and / or stop the automatic dispensing and packaging system and / or further system. Further optionally, the number of pouches and / or length of string of pouches in the buffer can be determined (e.g., by one or more sensors), and such information can be used for controlling input and / or output systems (e.g., starting and / or stopping systems).

[0012] According to an embodiment, each of the plurality of upper and lower rollers comprises an outer shoulder which has a diameter larger than a diameter of the roller. Such a shoulder can help to ensure that the string of pouches remains properly situated around each roller and does not slip off the end as the string of pouches moves through the dynamic buffering system.

[0013] According to an embodiment, each of the plurality of upper and lower rollers comprises one or more of: a soft material; a textured surface; a smooth surface, or a cylindrical brush. Such materials, configurations and / or textures can help to ensure that the string of pouches moves around rollers as intended, does not slip or stick, and can help to prevent damage to the pouches and / or contents therein when moving around rollers for buffering. In some cases, rollers could have a groove in a centre portion to help accommodate the tablets or medicaments in pouches without damage.

[0014] According to an embodiment, the system further comprises a drive and / or brake for at least one roller of the plurality of rollers. Such a drive and / or brake can help to ensure that the sting of packages move into and / or out of the dynamic buffering system as intended. Typically, the rollers are allowed to freely move or rotate as the sting of pouches move through the dynamic buffering system. By using a drive to drive one or more rollers, the string can be controlled coming into or moving out of buffering system. Similarly, a brake could ensure that the roller and therefore the string of pouches moves more slowly into or out of the buffering system. Such a drive and / or brake can also help to adjust the tension in the string of pouches as needed to reduce the chance that pouches and / or medicaments will be damaged from too much tension and / or that the string of pouches does not move properly from too little tension. For example, a brake (e.g., automatically operated) on the first roller of the buffering system (at the input) can help to prevent the string of pouches from being pulled into the buffering system when, for example, an operator has to remove a weld in the string of pouches between the dispensing machine and the buffering system and it is not desirable for the sting of pouches to move further into the buffering system.

[0015] According to an embodiment, the plurality of upper rollers can be moved below the plurality of lower rollers for loading and / or unloading. In such a system, for example, each of the plurality of upper rollers can be connected to an arm (e.g., vertically downward extending) and each of the plurality of lower rollers can also be connected to an arm (e.g., a vertically upward extending arm). The plurality of upper rollers can be, for example lowered manually, so that the lower rollers are automatically moved upwards with respect to the upper rollers. This brings both sets of rollers to an ergonomically correct working height, so that a string of foil can easily be fed through for starting up. When production starts, the plurality of upper rollers can be raised again (e.g., manually), with the bottom set of rolls following automatically because the string of pouches connects the upper and lower rollers. In some systems, a motor or other drive system can be used in place of or to assist the manual movements. Thus, the rollers can move such that they overlap each other for easier loading and / or unloading of a string of pouches through the middle of the rollers when positioned such that the upper rollers overlap (e.g., are below) the lower rollers.

[0016] According to a further aspect a system comprises an automatic dispensing and packaging system for producing a string of pouches; a further system to receive the string of pouches; and a dynamic buffering system to receive the string of pouches from the automatic dispensing and packaging system at the input side and output the string of pouches to the further system. The dynamic buffering system is configured to accommodate different numbers of pouches in the string of pouches according to the needs of the automatic dispensing and packaging system and the further system. Such a dynamic buffering system allows for connection between the two devices or systems despite non-synchronous operations, for example, differing input / output speeds or differing ways of working (e.g., continuous versus intermittent). This can result in an overall more efficient pouch production and further systems, such as an inspection system, as the time between production and inspection is reduced, which can also lead to finding and potentially intervening to resolve any issues at an earlier stage. Optionally, the buffering system can accommodate different numbers of pouches by expanding and / or contracting. Further optionally, any of the buffering systems previously described.

[0017] According to an embodiment, the automatic dispensing and packaging system and further system operate in a non-synchronous manner. For example, the automatic dispensing and packaging system outputs the string of pouches pouch-by-pouch continuously in a step-wise (pouch-by-pouch) manner. Optionally, the further system (e.g., an inspection system) receives pouches in an intermittent manner, continuously brining the string of pouches into the further system when receiving, but pausing completely for periods of time to have intermittent movement / receiving intervals overall. The dynamic buffering system allows for directly connecting a string of pouches between the automatic dispensing and packaging system and further system despite non-synchronous operation, for example, differing modes of operation, speed and / or stopping. This results in an overall more efficient system which requires less man-power and / or other systems to collect produced rolls from the automatic dispensing and packaging system and then take it over and feed it to the inspection system.

[0018] According to an embodiment, the dynamic buffering system is able to hold a differing length of string of pouches by the plurality of upper rollers and / or the plurality of lower rollers moving to extend or reduce the distance between the plurality of upper rollers and the plurality of lower rollers. Typically, the lower rollers move along a frame extending substantially vertically, thereby allowing movement through gravity and not requiring additional movement systems. This results in a simple yet effective way of automatically changing the length of string of pouches being buffered according to the needs at the time.

[0019] According to an embodiment, the further system is an inspection system. Optionally, the inspection system comprises a second buffering system to buffer the string of pouches which have been inspected by the inspection system but are waiting on a visual inspection. Optionally, the second buffering system buffers rolls of strings of pouches which have been inspected by the inspection system. Such a second buffering system can allow for a closer-in-time visual inspection (e.g., by an operator) of pouches which have been flagged as possibly defective by the inspection system than in past systems which only did visual inspections much later. By buffering the pouches for visual inspection, a final determination of whether there is a defect in a pouch can be determined more quickly and such rolls can be separated for correction at the exit of the inspection system (instead of found later as in past systems). Thus, such a second buffering system can improve the overall efficiency of the system, particularly with respect to rolls or pouches that may be incorrectly identified as having a possible defect by the inspection machine but in which a visual inspection confirms there is no defect. Such second buffering system could involve a switch with different baskets for various categories of rolls; an elevator system or any number of differing buffering systems and devices.

[0020] According to a further aspect, a method of buffering a string of pouches between a first system outputting the string of pouches and a second system receiving the string of pouches comprising feeding the string of pouches in an alternating manner between a plurality of upper rollers and a plurality of lower rollers. One set of the plurality of upper rollers and the plurality of lower rollers is moveable with respect to the other set of the plurality of upper rollers and the plurality of lower rollers to buffer varying lengths of the string of pouches between the first system and the second system. Such a system allows for dynamically and automatically buffering differing lengths of a string of pouches, allowing for connections between the first and second systems which may have differing speeds, working time and / or input / output modes.

[0021] According to an embodiment, the first system outputs the string of pouches in a non-synchronous manner with respect to the second system. For example, the first system could output the string continuously producing one pouch at a time; and the second system could receive the string of pouches in an intermittent manner, at a fast and steady continuous flow when receiving but stopping the receiving for periods of time. The buffering system allows for expanding by moving the plurality of upper rollers and / or the plurality of lower rollers to allow for more pouches in the buffering system when the second system is not receiving pouches or is receiving pouches more slowly than the first system outputs pouches to the string. Then when the second system starts to receive pouches again, the rollers can move to accommodate fewer pouches as the string moves into the second system.

[0022] According to an embodiment, the method further comprises buffering the pouches in the second system for visual inspection. Such a second buffering system can allow for additional manual steps (e.g., manual visual inspection of any flagged pouches) to be taken while the pouches are still in the second system instead of having to take the manual steps at a later time. Thus, this can result in an overall more efficient system and process and less time between production, determination of defects and possible interventions to fix issues causing or resulting in defects.

[0023] The various aspects and features described and shown in the specification can be applied, individually, wherever possible. These individual aspects, in particular the aspects and features described in the attached dependent claims, can be made subject of divisional patent applications.

[0024] BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The invention will be elucidated on the basis of an embodiment shown in the attached schematic drawings, in which: Figure 1 shows a front view of a prior art automated dispensing and packaging system;

[0026] Figure 2A shows a perspective view of an automated dispensing and packaging system, a buffering system and an inspection system;

[0027] Figure 2B shows a front view of the systems of Fig. 2 A;

[0028] Figure 3 A shows a perspective view of a buffering system, Figure 3B shows a front view of the buffering system of Fig. 3 A;

[0029] Figure 3C shows a view of the buffering system of Fig. 3 A in an expanded state; and

[0030] Figure 3D shows a view of the buffering system of Fig. 3A in a loading / unloading position.

[0031] DETAILED DESCRIPTION OF THE INVENTION

[0032] Figure 2A shows a perspective view of part of an automated dispensing and packaging system 10 which is similar to the system 1 shown and described as prior art in relation to Fig. 1. However, automated dispensing and packaging system 10 does not include a collection station 6 with reel 60, and instead, the string S of pouches is fed directly into buffering system 70 and then to inspection system 90. Automated dispensing and packaging system 10 produces pouches P in a continuous manner, moving string S forward by producing pouches continuously.

[0033] Buffering system 70 includes vertical frame 72 with base 74, a plurality of upper rollers 76a, 76b, 76c, 76d, 76e, 76f rotatably connected to upper frame 78; and a plurality of lower rollers 80a, 80b, 80c, 80d, 80e, 80f rotatably connected to lower frame 82. At least one of the plurality of upper rollers 76a-76f and the plurality of lower rollers 80a-80f is moveable along vertical frame 72 to allow for buffering more or fewer pouches (and string S length) depending on automated dispensing and packaging system 70 and / or inspection system 90 needs at any particular time. Frame 72 extends substantially vertically upward from base 74, to supports buffering system 70, though other embodiments could be supported in a different manner (e.g., via multiple frames, on a wall, etc.). Base 74 can be weighted and / or have various configurations to effectively manage the forces from string S of pouches travelling through buffering system 70, and provide stability for buffering system 70. In the embodiment of buffering system 70 shown in Figs. 2A-2B, lower frame 82 is moveable along frame 72 (e.g., along a track) to move lower rollers 80a, 80b, 80c, 80d, 80e, 80f closer to or further away from upper frame 78 (and upper rollers 76a, 76b, 76c, 76d, 76e, 76f ) depending on the buffering needs at any particular time. Lower frame 82 can simply move under the weight of gravity to different positions depending on the length of string S of pouches in buffering system 70 at a particular time, or in some cases can be weighted, driven, connected to a spring or other mechnism to ensure that frame 82 moves downward to keep tension on string S at all times, which can be particularly useful when pouches and / or the contents of pouches are very light-weight. Upper frame 78 is connected to frame 72 such that it does not move with respect to frame 72 when buffering system 70 is in use, though upper frame 78 could have different “set” positions along vertical frame 72 that it could be set at for various operations (e.g., be moveable to bet set at different positions for varying overall buffering capacity of the buffering system). Additionally, upper frame 78 could be connected to a motor, pulley or other drive mechanism to assist in moving position of upper frame 78 when desired or necessary.

[0034] As can be seen in Figs. 2A-2B, the string of pouches S connects around the upper rollers 76a-76f and lower rollers 80a-80f in an alternating manner from an input side 84 to an output side 86. Generally, rollers 76a-76f, 80a-80f are connected to respective frames 78, 82 such that they can freely rotate with the movement of string S of pouches moving from the automated dispensing and packaging system 10 to the inspection system 90. Input side 84 and / or output side 86 could in some embodiments start / end with a driven roller (e.g., a roller which is connected to a motor which can drive the specific roller) and / or a roller with a brake to better control the movement and tension in string S of pouches. Such drive means and / or braking means could be associated with an upper and / or a lower roller or set of rollers.

[0035] Inspection system 90 receives the string S of pouches from buffering system 70 for inspection of the pouches P, for example, inspecting for one or more of: correct number and / or type of medicaments, damage to medicaments, damage to a pouch, etc. Such an inspection system typically takes in pouches in an intermittent manner for inspection, continuously and at a fast speed when intaking for inspection but often pausing intake of pouches for periods of time. Inside the machine, pictures are taken of each pouch, an automated analysis is performed (e.g., a comparison is made with a database of what the inspection machine would expect a picture of a non-defective pouch with the correct medicaments would look like for each pouch), specific pouches are flagged to indicate there may be an issue (e.g., they do not align closely enough with the expected picture), and flagged pictures are sent to be reviewed for a final visual inspection to determine whether there is a defect which needs to be fixed. This final visual inspection is typically done by an operator. In some inspection systems 90, the flagging may be related to a comparison with other pouches in the string S which should have the same or similar contents, and any pouches which appear to differ are flagged for further visual inspection. After taking the pictures and doing the initial flagging, the inspection machine can wind the pouches onto a reel that is eventually processed into patient rolls.

[0036] Some embodiments of the systems disclosed could include a second buffering system 100 near or within inspection system 90 to allow for close in time visual inspection of flagged pouches. In past systems, inspection system 90 would flag pouches while making reels of strings of pouches, and only present an operator with pictures of flagged pouches after a number of reels had been formed, typically over a number of hours. The operator then needed to go through the pictures, make a final determination of whether there was a defect which needed to be fixed, and then sort through the reels to find the ones with a defect. By having a second buffering system 100 (e.g., a holding crate with a switch) near or within inspection system 90, an operator could be presented with the flagged pictures shortly after the flagging determination, and make a final decision of whether the pictured pouch has a defect while the reel is within the second buffering system 100. If the operator determines that the reel includes a defect, a switch could send the reel to a defect pile, thereby identifying defects at an earlier stage and not requiring the operator to sort through all the reels to find specific ones with a defect. Additionally, by identifying defects at an earlier stage, the time between production and final inspection is reduced and an operator could potentially identify a source of the defects (e.g., a malfunctioning feeder unit) and thereby intervene to avoid future defects as well (e.g., replace the malfunctioning feeder unit).

[0037] Buffering system 70 allows for the direct connection of automated dispensing and packaging system 10 and inspection system 90 despite operating non-synchronously. For example, automated dispensing and packaging system 10 produces pouches in a continuous (but step-wise or pouch by pouch) manner and inspection system 90 takes in the string S of pouches in an intermittent manner (only during intermittent periods). Buffering system 70 allows for automated dispensing and packaging system 10 to continuously product pouches, allowing for buffering large amounts of pouches when necessary by lower frame 82 moving lower rollers 80a, 80b, 80c, 80d, 80e, 80f downward to expand the length of the string S of pouches in buffering system 70. Then, when inspection system 90 is able to start or restart inspections, buffering system is able to easily and automatically adjust to buffering a shorter string S of pouches by lower frame 82 (with lower rollers 80a, 80b, 80c, 80d, 80e, 80f ) moving vertically upward toward upper frame 78 (with upper rollers 76a, 76b, 76c, 76d, 76e, 76f ) as pouches are taken into inspection system 90, thereby reducing the total length of the string S in buffering system 70. Additionally, the large and dynamically changing buffering capacity (by expanding or contracting) allows for connecting systems that work at different speeds and / or in which one or both have to be periodically paused (e.g., for a final review of flagged pouches, maintenance operations, restocking materials, etc.). Thus, for example, if inspection system 90 is paused for an operator to make a visual inspection of flagged pouches, automated dispensing and packaging system 10 can continue to produce pouches which will simply be fed into buffering system 70 that will expand (move lower rollers further away from upper rollers) to hold the produced number of pouches until inspection system 90 restarts. Inspection system 90 can then operate to intake pouches at a higher speed than automated dispensing and packaging system 10 produces pouches, and buffering system automatically adjusts to accommodate the shorter string S with tension.

[0038] Thus, buffering system 70 allows for connecting systems which are non- synchronous, have varying speeds and / or input or output modes (e.g., intermittent or stopping versus continuous), by allowing for dynamic buffering, changing the length of string S of pouches buffered depending on the needs at any time. This can result in a decrease of total production time and decrease of the time between production and inspection.

[0039] Figure 3A shows a perspective view of buffering system 70, Figure 3B shows a front view of buffering system 70, Figure 3C shows a view of buffering system 70 in an expanded state, and Fig. 3D shows a view of the buffering system 70 in a loading / unloading position. As discussed in relation to Figs. 2A-2B, buffering system 70 is formed of frame 72 on base 74, upper frame 78 with a plurality of upper rollers 76a-76f; and lower frame 82 with a plurality of lower rollers 80a-80f. Each of upper frame 78 and lower frame 82 connect to frame 72, through either a fixed or moveable connection, allowing at least one of the frames to move up and down along frame 72. In this case, lower frame 82 moves along frame 72 which upper frame 78 is fixed with respect to frame 72.

[0040] Rollers 76a-76f and 80a-80f can have various surface textures and / or configurations depending on the medicaments or tablets and pouch materials and configuration. For example, rollers could have a textured surface (e.g., a cylindrical brush roller or other texture), a wavy surface and / or a smooth surface. Materials could be a softer, more flexible material or a hard plastic such as polyvinyl chloride (“PVC”). Each roller can also have a shoulder 81 on an outer and / or inner end which has a diameter larger than a diameter of the roller, for example 5-50% larger. This helps to ensure that the string S of pouches remains connected around the respective rollers as it moves through buffering system 70 and does not slip off the end of a roller.

[0041] Upper frame 78 and lower frame 82 are generally horizontally extending frames, though can have some height as well as seen in the embodiments shown in Figs. 3 A-3D. In some embodiments, upper rollers 76a-76f can be mounted vertically lower than the horizontally extending part of upper frame 78 and lower rollers 80a-80f can be mounted vertically higher than the horizontally extending part of lower frame 82. This can be through arms 88, as seen in buffering system 70. Such mounting at an offset position can allow for easier mounting and / or removal of the string S of pouches into or out of buffering system 70. For mounting string S, lower frame 82 could be moved vertically upwards along vertical frame 72 such that lower rollers 80a-80f are located higher than upper rollers 76a- 76f (see Fig. 3D). While in such a position, string S of pouches could be positioned straight between rows of rollers 76a-76f and 80a-80f. Then lower frame 82 can be moved in a downward direction, and string S of pouches would alternate between the upper rollers and lower rollers as shown in Figs. 2A-3C. Alternatively, the plurality of upper rollers 76a- 76f can also be lowered manually, so that the lower rollers 80a-80f are automatically moved upwards with respect to the upper rollers 76a-76f. This can bring both sets of rollers to an ergonomically correct working height, so that the string S of pouches can easily be fed through for starting up. When production starts, the upper frame 78 with the plurality of upper rollers 76a-76f can be raised again (e.g., manually and / or with the help of a motor or other drive mechanism), with the lower frame 82 with the set of lower rollers 80a-80f following automatically because the string of pouches connects the upper and lower rollers 76a-76f and 80a-80f. In some systems, a motor or other drive system can be used in place of or to assist the manual movements.

[0042] When buffering system 70 needs to take in a longer length of string S of pouches, lower frame 82 moves even further downwards to expand buffering capacity to accommodate more pouches (and length of string of pouches) into buffering system 70, as seen in Fig. 3C. Buffering system 70 can also include one or more sensors, for example, position sensors, to sense and issue an alarm or warning (e.g., at a user interface) if the buffering system 70 is reaching an upper or lower limit. For example, if inspection system 90 is stopped, but automated dispensing and packaging system 10 continues to produce pouches, buffering system 70 will expand by moving lower frame 82 downward as seen in Fig. 3C. At a certain point, lower frame 82 cannot move further downward, and a sensor could send a signal to issue a warning that buffering system 70 is at or near capacity and automated dispensing and packaging system 10 must either stop producing pouches or inspection system 90 much start pulling the string of pouches out of buffering system for inspection.

[0043] Such stopping and / or starting could be automated in some embodiments, for example, through a control system. Such a control system (or other system) could also share data between the devices and systems. For example, the automated dispensing and packaging system 10 could send data to the inspection system 90 and vice versa to allow the systems to know when one may have to stop or slow down to accommodate the pouch movements with relation to the other and the buffering system 70. In another example, the buffering system 70 could send data regarding capacity to the automated dispensing and packaging system 10 and / or the inspection system 90 to enable each to slow down, stop or speed up to ensure there is enough capacity in buffering system for optimal overall performance.

[0044] Overall, the buffering methods and systems shown and described allow for directly connecting a string S of pouches between two separate systems which do not operate synchronously and may work at different speeds and / or in different intake / output modes. In the examples shown, the connection is between automated dispensing and packaging system 10 and inspection system 90, thereby making for an overall more efficient dispensing, packaging and inspection process despite the systems working at differing speeds and / or in differing output / intake manners (e.g., intermittent versus continuous). The ability to buffer different lengths of strings of pouches through moveable sets of rollers also allows for accommodating intermittent stopping and starting of each system as required for various operations, particularly inspection. The configuration and material of rollers can ensure proper movement of the string S of pouches through buffering system 70 without damaging medicaments, pouches or the string despite pouches typically including perforations and / or tear notches. While the method has been described in detail in relation to medicament dispensing, packaging and inspection systems and processes, the methods and systems could be applicable to other production processes as well, allowing for directly connecting systems which do not operate synchronously. While the description refers to medicaments, tablets, etc., the devices and methods could be used for dispensing other types of solid discrete items for separation, packaging and inspection.

[0045] It is to be understood that the above description is included to illustrate the operation of the embodiments and is not meant to limit the scope of the invention. From the above discussion, many variations will be apparent to one skilled in the art that would yet be encompassed by the spirit and scope of the present invention.

Claims

CLAIMS:

1. A dynamic buffering system for buffering a string of pouches produced in an automatic dispensing and packaging system, the buffering system comprising: a plurality of upper rollers connected to an upper frame; a plurality of lower rollers connected to a lower frame; a frame to which the upper frame and / or the lower frame connect; wherein the upper frame with the plurality of upper rollers and / or the lower frame with the plurality of lower rollers is moveable along the frame such that the buffering system can be expanded or contracted to hold more or fewer pouches in the string of pouches; and wherein the string of pouches connects around the plurality of upper rollers and lower rollers in an alternating fashion from an input side to an output side.

2. The dynamic buffering system of claim 1, wherein the upper frame and the lower frame connect to the frame.

3. The dynamic buffering system of any of the preceding claims, wherein the lower frame is moveable along the frame.

4. The dynamic buffering system of any of the preceding claims, wherein the plurality of lower rollers and / or the plurality of upper rollers is driven.

5. The dynamic buffering system of any of the preceding claims, wherein the plurality of lower rollers and / or the plurality of upper rollers is weighted and / or connected to a spring.

6. The dynamic buffering system of any of the preceding claims, wherein each of the plurality of upper and lower rollers comprises an outer shoulder which has a diameter larger than a diameter of the roller.

7. The dynamic buffering system of any of the preceding claims, wherein each of the plurality of upper and lower rollers comprises one or more of: a soft material; a textured surface; a smooth surface; a cylindrical brush.

8. The dynamic buffering system, and further comprising a drive and / or brake for at least one roller of the plurality of rollers.

9. The dynamic buffering system, wherein the plurality of upper rollers can be moved below the plurality of lower rollers for loading and / or unloading.

10. A system comprising: an automatic dispensing and packaging system for producing a string of pouches; a further system to receive the string of pouches; and a dynamic buffering system according to any of claim 1-9.

11. The system of claim 10, wherein the automatic dispensing and packaging system and the further system operate in a non-synchronous manner.

12. The system of any of claims 10-11, wherein the further system receives pouches in a continuous manner for intermittent intervals; and / or wherein the automatic dispensing and packaging system outputs pouches continuously in a pouch-by-pouch manner.

13. The system of any of claims 10-12, wherein the dynamic buffering system is able to hold a differing length of string of pouches by the upper frame and / or the lower frame moving to extend or reduce the distance between the plurality of upper rollers and the plurality of lower rollers.

14. The system of any of claims 10-13, wherein the further system is an inspection system, and the system further comprises a second buffering system to buffer the string of pouches which have been inspected by the inspection system but are waiting on a visual inspection.

15. The system of claim 14, wherein the second buffering system buffers rolls of strings of pouches which have been inspected by the inspection system.

16. A method of buffering a string of pouches between a first system outputting the string of pouches and a second system receiving the string of pouches, the method comprising: feeding the string of pouches in an alternating manner between a plurality of upper rollers connected to and moveable with an upper frame and a plurality of lower rollers connected to and moveable with a lower frame; wherein at least one of the upper and lower frames is moveable with respect to the other of the upper and lower frames to buffer varying lengths of the string of pouches between the first system and the second system.

17. The method of claim 16, wherein the first system outputs the string of pouches in a non-synchronous manner with respect to the second system receiving the string of pouches.

18. The method of any of claims 16-17, and further comprising: buffering the pouches in the second system for visual inspection.

Images