Methods, feeder units and dispensing systems for dispensing discrete medicaments

Abstract

A method of selective emptying of a feeder unit in a dispensing device comprises a) dispensing tablets from the feeder unit at a first speed (S1); and b) when a fill level of the feeder unit meets a threshold, performing one of: b1) dispensing tablets from the feeder unit at a second speed (S2), wherein the second speed (S2) is different than the first speed (S1); or b2) ejecting the feeder unit from the tablet dispensing device.

Description

[0001] METHODS, FEEDER UNITS AND DISPENSING SYSTEMS FOR DISPENSING

[0002] DISCRETE MEDICAMENTS

[0003] BACKGROUND

[0004] This relates to methods, feeder units and dispensing systems for dispensing discrete medicaments.

[0005] A method for dispensing a medicament from a feeder unit is discussed in WO 2014 / 171818, wherein the method comprises the steps of accommodating one or more of said medicaments in a single row, in one of a plurality of singulation chambers of a singulating body; and moving said singulating body with respect to a first release member arranged below said singulating body and provided with an release opening, to align one of said plurality of singulation chambers with said release opening. A separating member extends out into or over said one of said plurality of singulation chambers substantially blocking said one of said plurality of singulation chambers above a lower most medicament in said one of said plurality of singulation chambers. The lower most medicament falls through said release opening into one of a plurality of waiting chambers of a storage body which is arranged below said first release member. A filling of said one of a plurality of waiting chambers is detected by the use of a detection arrangement for at least facilitating the detection whether or not one or more of said waiting chambers are filled with the medicament(s). The storage body is moved with respect to a second release member arranged below said storage body and provided with an dispensing opening. The movement is to align one of said plurality of waiting chambers with said dispensing opening, wherein the medicament(s) in said one of said plurality of waiting chambers falls through said dispensing opening and is dispensed out of the feeder unit. Thus, one or more medicaments are controllably dispensed from the feeder unit.

[0006] SUMMARY OF THE INVENTION

[0007] As described above, in the feeder unit according to the prior art, a medicament (such as a tablet or capsule) is received in a waiting chamber of the storage body from the singulating body. In order to reliably dispense the medicament from the feeder unit, the waiting chambers of the storage body have to be filled reliably. Therefore, the singulating body is rotated until a drop of a tablet into one of the waiting chambers is detected. If the singulating body is rotated too quickly, the medicament tends to skip over the singulation chambers of the singulating body. This happens even more frequently when the feeder unit is getting close to being empty. Additionally, certain medicaments have higher tendencies to skip. Using a slow rotation speed can help to reduce the chances of skipping and ensure a feeder unit empties completely, but a slow rotation speed is disadvantageous as the overall dispensing speed of the feeder unit is then determined by the slowly rotating singulating body.

[0008] Furthermore, in the prior art, feeder units are usually filled with a specific medicament, such as tablets or capsules, and then completely emptied before ejecting from a dispensing system to refill or replace the feeder unit. Thus, slower rotation can be necessary to ensure that the feeder unit is completely emptied and no tablets are wasted.

[0009] It is an object of the present invention to ameliorate or to eliminate one or more disadvantages of the prior art, to provide an improved dispensing method or system or to at least provide an alternative method, feeder unit and dispensing system for dispensing discrete medicaments.

[0010] According to a first aspect, a method of selective emptying of a feeder unit in a dispensing device comprises a) dispensing tablets from the feeder unit at a first speed (Si); and b) when a fill level of the feeder unit meets a threshold, performing one of: bl) dispensing tablets from the feeder unit at a second speed (S2), wherein the second speed (S2) is different than the first speed (Si); or b2) ejecting the feeder unit from the tablet dispensing device.

[0011] Such a method provides a more efficient overall method of dispensing from a feeder unit by varying the speed of dispensing based on a fill level of a feeder unit and whether the fill level meets a threshold T, and / or ejecting a feeder unit when it meets a threshold - before it is empty. The threshold could be, for example, at a certain percentage of fill of the feeder unit (e.g., 10%), at a certain tablet count or another indicator of fill level. The threshold could also vary depending on the feeder unit, tablets in the feeder unit, etc. By varying the speed according to a fill level threshold, a faster speed can be used for most dispensing operations and a slower speed could be used only when necessary (e.g., when a fill level is low and thus there is a higher chance of tablets skipping if higher rotation speeds are continued). In ejecting at the threshold (instead of dispensing until empty), the higher speed dispensing can continue and there is no need for a second (e.g., slower) speed.

[0012] According to an embodiment, the second speed (S2) is slower than the first speed (Si). Such a slower second speed helps to reduce or eliminate the chance of skipping or tablets not entering a singulation chamber for dispensing upon rotation. This is particularly useful when a fill level of the feeder unit is such that it is prone to skipping and / or at a set or determined threshold.

[0013] According to an embodiment, step bl) comprises dispensing tablets from the feeder unit at the second speed (S2) until the feeder unit is empty. Thus, the feeder unit can be completely emptied at a speed which reduces or eliminates the chance of skipping, thereby ensuring that little to no tablets are wasted and that additional rotations and time for emptying (due to tablet skipping) is not needed.

[0014] According to an embodiment, step bl) comprises dispensing tablets from the feeder unit at the second speed (S2) until the feeder unit meets an ejection threshold; and then ejecting the feeder unit from the dispensing device. The ejection threshold could be, for example, related to a specific number or weight of tablets in which a dispense is less likely, for example at 5-10 tablets. At such a time, the feeder unit could be ejected, and then refilled instead of dispensing until fully empty. This can make for more efficient operations if, for example, tablets did not dispense reliably after an ejection threshold level. Then the feeder unit is simply ejected at this point.

[0015] According to an embodiment, the method further comprises the step of: when a fill level of the feeder unit meets a full threshold, dispensing tablets from the feeder unit at a third speed (S3) until the full threshold is crossed, wherein the third speed (S3) is different than the second speed (S2) and the first speed (Si). Optionally, the full threshold is associated with a very full feeder unit and the threshold is associated with an almost empty feeder unit, and wherein the first speed (Si) is greater than the second speed (S2) and the third speed (S3). Further optionally, the third speed (S3) is greater than the second speed (S2) and the dispensing of tablets at the second speed (S2)is until the feeder unit is empty. Such a full threshold and third speed can further increase efficiency of overall operations while helping to ensure that the rotation speed is appropriate for the fill level of the feeder unit at the time. For example, when very full it may be useful to dispense at a lower than normal speed until the full threshold is passed. This could help to ensure the larger mass / weight of tablets in a very full feeder unit does not result in medicaments not being properly dispensed. Once the full threshold is crossed, the speed can increase to the first (e.g., normal) dispensing speed until the threshold is met indicating the feeder unit is almost empty and may need a lower speed (e.g., the second speed) to ensure proper dispensing.

[0016] According to an embodiment, when a fill level of the feeder unit meets a threshold and the feeder unit is ejected from the device, the method further comprises dispensing from a second feeder unit. Optionally, the dispensing from the second feeder unit is at the first speed if a fill level of the second feeder unit is above the threshold. Such dispensing from a second feeder unit can continue the dispensing at efficient speeds (e.g., while the first feeder unit is being ejected for refilling). Thus, overall dispensing can continue efficiently.

[0017] According to an embodiment, when a fill level of the feeder unit meets a threshold and the feeder unit is ejected for refilling, the method further comprises: c) refilling the feeder unit; d) inserting the refilled feeder unit back into the tablet dispensing device; and e) dispensing tablets from the feeder unit.

[0018] Optionally, step e) comprises dispensing tablets from the feeder unit at the first speed. Such a method allows for dispensing at efficient speeds by ejecting and refilling a feeder unit before it gets to a fill level where it is prone to skipping and therefore needs slower dispensing speeds to ensure that tablets are properly dispensed with each rotation.

[0019] According to an embodiment, steps b), b2), c), d) and e) are performed a set number of times before step bl) is performed. The set number of times can be, for example, 1-10 times or over a certain time period. Optionally, the set number of times is related to one or more of: an expiry date of the tablets, a pouch consumption date; and a lot number of the tablets. By ejecting and refilling a feeder unit one or more times prior to fully emptying, dispensing at faster speeds can continue for longer (more tablets can be dispensed at faster dispensing speeds) before slowing down for full emptying of a feeder unit. Only when it is necessary does a feeder unit perform step bl), moving to a different speed for full emptying. Such a determination can be made based on one or more inputs which are related to the tablets and / or pouch consumption. Alternatively, such a determination could be made based on different criteria, such as the upcoming jobs and / or the number of times a feeder unit has already been refilled without emptying and / or how a feeder unit is performing. By only fully emptying the feeder unit periodically and refilling instead when a threshold is met, the overall dispensing of tablets can be performed more efficiently.

[0020] According to an embodiment, the first speed and second speed are related to a rotation speed of a singulating body. Alternatively, this could be in relation to a rotation speed of a storage body. The speeds can be the speed at which a singulating body rotates, which singulates tablets from a storage container and feeds to an opening or outlet upon rotation. Relating the dispensing speeds to rotation speed of a singulating and / or storage body is a simple way to control the dispensing speed from a feeder unit.

[0021] According to a further aspect, a dispensing system accommodating one or more feeder units is provided. The dispensing system is arranged for selectively dispensing an amount of discrete medicaments from the one or more feeder units, and the system comprises a dispensing device provided with an array of dispensing positions, wherein the dispensing device at each of said array of dispensing positions is provided with a holder for one of the feeder units and with a through opening for passing discharged medicaments therethrough, and a control unit for controlling the working of the system and the one or more feeder units arranged on the dispensing device. The control unit is configured to cause at least one of the one or more feeder units to: a) dispense tablets from the feeder unit at a first speed (Si); and b) when a fill level of the feeder unit meets a threshold, perform one of the following: bl) dispense tablets from the feeder unit at a second speed (S2), wherein the second speed (S2) is different than the first speed (Si); or b2) eject the feeder unit from the dispensing system.

[0022] Such a system is able to efficiently dispense tablets from the feeder unit as a first (e.g., faster) speed is used until a threshold is met, after which it is determined to use a second (e.g., lower) speed to empty the feeder unit, or eject the feeder unit (e.g., for refilling). Thus, the system provides for overall efficient dispensing from the feeder units.

[0023] According to an embodiment, the feeder unit comprises a dispensing mechanism which operates according to the methods herein described, for example at different speeds depending on a fill level of the feeder unit. Optionally, the dispensing mechanism comprises one or more of: a singulating body, a separating member, a storage body with one or more waiting chambers and a release member. In an example, the singulating body and / or the storage body are rotatable for moving medicaments from a chamber in the feeder unit through the dispensing mechanism and dispensing the medicament. The speeds of the methods can in some embodiments refer to the rotation speed of one or more parts of the dispensing mechanism, for example, the singulating body receiving medicaments from a chamber in the feeder unit.

[0024] According to an embodiment, the system comprises a collection device arranged below the dispensing device, wherein the collection device and the dispensing device are movable with respect to each other, wherein the collection device is provided with a number of collection trays, wherein each of the trays comprises a receiving opening at a side facing the dispensing device for receiving discharged medicaments and each comprises an output. Optionally, the system further comprises a packaging unit for collecting the received medicaments from the output of a tray and packaging the medicaments. Such a system can efficiently dispense tablets for collecting and packaging.

[0025] According to an embodiment, the second speed (S2) is slower than the first speed (Si). Optionally, the control unit is further configured to control, in step bl), the feeder unit to dispense tablets from the feeder unit at the second speed (S2) until the feeder unit is empty. By only dispensing at the second, slower speed when a fill level of the feeder unit meets a threshold, faster, more efficient dispensing can be performed for most of the dispensing operations. Thus, the slower dispensing, which can help to reduce or eliminate the chance of tablets skipping, is only used for a short time triggered by the fill level of the feeder unit meeting or goes below the threshold.

[0026] According to an embodiment, the control unit is further configured to control, in step bl), the feeder unit to dispense tablets from the feeder unit at the second speed (S2) until the feeder unit meets an empty threshold, and then eject the feeder unit. Thus, the feeder unit could be ejected at the empty threshold, e.g., a weight or tablet count where dispense is not always reliable. This provides for more efficient overall operations by simply ejecting at such an empty threshold, whereupon the feeder unit could be refilled. According to an embodiment, the control unit is further configured to control the system to, when a fill level of the feeder unit meets a full threshold, dispense tablets from the feeder unit at a third speed (S3) until the full threshold is crossed, wherein the third speed (S3) is different than the second speed (S2) and the first speed (Si). Optionally, the full threshold is associated with a very full cannister and the threshold is associated with an almost empty cannister, and wherein the first speed (Si) is greater than the second speed (S2) and the third speed (S3). Further optionally, the third speed (Ss)is greater than the second speed (S2) and the dispensing of tablets at the second speed (S2) is until the feeder unit is empty. Such a full threshold and third speed can provide for further control of the dispensing speed according to the fill level (e.g., allowing for slower dispensing when the feeder unit is very full) to ensure efficient and reliable dispensing operations no matter the fill level of the feeder unit.

[0027] According to an embodiment, the control unit is further configured to, when a fill level of the feeder unit meets a threshold and the feeder unit is ejected from the system, control the system to dispense from a second feeder unit. Optionally, the control unit is configured to control the dispensing from the second feeder unit to be at the first speed if a fill level of the second feeder unit is above the threshold. Thus, the system can continue efficient dispensing operations, preferably at the first speed from the second feeder unit while the first feeder unit is being ejected (e.g., for refilling).

[0028] According to an embodiment, the control unit is configured to, when a fill level of the feeder unit meets a threshold and the feeder unit is ejected for refilling, cause the system to provide instructions for: c) refilling the feeder unit; d) inserting the refilled feeder unit back into the tablet dispensing device; and e) dispensing tablets from the refilled feeder unit.

[0029] Optionally, step e) comprises dispensing tablets from the feeder unit at the first speed. Such a system allows for dispensing more tablets and for longer periods of time at a first (e.g., fast) speed by instructing feeder units to be refilled instead of dispensing until empty and reducing the dispensing speed accordingly when the threshold has been met or gone below.

[0030] According to an embodiment, the control unit controls the system to perform steps b), b2), c), d) and e) a set number of times before step bl) is performed. Optionally, the set number of times is related to one or more of: an expiry date of the tablets, a pouch consumption date; and a lot number of the tablets. By ejecting and refilling a set number of times according to one or more criteria related to the tablets and / or system, the system can dispense more efficiently than past systems which dispensed at one speed and / or always dispensed until the feeder unit was empty (instead of ejecting for refilling when a fill level meets a threshold).

[0031] According to an embodiment, wherein the feeder unit comprises a rotatable singulating body, and the dispensing speed relates to the rotation speed of the singulating body. Optionally, the feeder unit could also comprise a storage body and / or the speed could be in relation to a rotation speed of a storage body. The dispensing speeds can be the speed at which a singulating body rotates, which singulates tablets from a container and feeds to an opening or outlet of the feeder unit upon rotation. Relating the dispensing speed to the rotation speed of a singulating and / or storage body is a simple way to control the dispensing speed from a feeder unit.

[0032] 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.

[0033] BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The invention will be elucidated on the basis of an embodiment shown in the attached schematic drawings, in which:

[0035] Figure 1 shows a view a dispensing system having a dispensing device provided with an array of dispensing positions for accommodating a number of feeder units for selectively dispensing an amount of medicaments from one or more feeder units and for packaging the dispensed amount,

[0036] Figure 2 shows a schematic top view of the dispensing system of the embodiment of figure 1,

[0037] Figure 3 shows a schematic view of a feeder unit,

[0038] Figure 4 shows a schematic cross section of the dispensing mechanism of the feeder unit of figure 3,

[0039] Figures 5A-5B show views of a feeder unit at different fill levels; and Figure 6 shows a schematic diagram of the steps of a method for dispensing tablets from a feeder unit.

[0040] DETAILED DESCRIPTION OF THE INVENTION

[0041] Figure 1 shows an automatic or automated dispensing device and system 1 for dispensing and packaging discrete medicaments M into a plurality of medicament packages P which are intended for containing discrete medicaments M dispensed and packaged by said automated dispensing device.

[0042] The discrete medicaments M can be discrete solid medicaments, pharmaceuticals or solid items, articles or substances, e.g. pills, tablets, capsules or the like for medical use. The medicaments or tablets are ‘discrete’ in the sense that they can be dispensed one-by-one, individually, separately or in dose units.

[0043] The dispensing device 1 comprises a housing 10 which defines a dispensing section 2, a collection section 3 and a packaging section 4. The dispensing device 1 further comprises a control unit 7 holding a processor 8 and memory 9, for example a structured database. The control unit 7 is configured for controlling and monitoring the production processes of the dispensing device 1.

[0044] The dispensing section 2 accommodates a plurality of feeder units 20 (e.g., cannisters or tablet cases) held in a circular array of feeder positions, similar to the device in US 2014 / 0366489 Al, the contents of which are incorporated herein by reference. Each feeder position comprises a docking member for mating with or receiving a respective one of the feeder units 20, with an appropriate aperture or channel to allow passage of dispensed medicaments M through the feeder position into the collection section 3 underneath. The array of feeder positions is distributed along an endless collection path Z. In this example, the endless collection path Z is circular or substantially circular and the array of feeder positions is distributed circumferentially about a rotation axis . More in particular, the array of feeder positions is distributed circumferentially or according to a radial grid, e.g. in a plurality of radially extending rows arranged side-by-side or adjacent in a circumferential direction about the rotation axis R. Preferably, the housing 10 extends cylindrically around the array of feeder positions. In this example, the circumferential walls of the housing 10 are provided with a plurality of stock positions 12 for holding temporarily unused or auxiliary feeder units 20. The dispensing device 1 is further provided with a robotic manipulator 11, e.g. which can include a robot arm, for automatic, automated or autonomous handling, positioning, removing and / or repositioning the feeder units 20 with respect to the array of feeder positions. The robotic manipulator 11 is provided with a gripper head to pick-and- place the feeder units 20. In this embodiment, the robotic manipulator 11 is located at the center of the array of feeder positions, e.g. close to, at or near the rotation axis R. In said position, all feeder positions and stock positions are conveniently within reach of the robotic manipulator 11.

[0045] Each feeder unit 20 comprises a container 50 for holding a stock of the discrete medicaments M, a dispensing mechanism 60 for singulating the discrete medicaments M and an outlet for dispensing the singulated discrete medicaments M one- by-one. The dispensing section 2 can further comprise a feeder loading member 24 with one or more feeder loading positions 25 for receiving new feeder units 20 into the dispensing device 1 and / or for ejecting feeder units 20 from the dispensing device 1. In this example, the feeder loading member 24 is formed as a drawer. Alternatively, a door or the like may be used. The dispensing section 2 may optionally comprise a manual loading position 26 for receiving a manual loading member (not shown), e.g. a medicine transport plate, that is manually loaded with medicaments M which are unsuitable to be dispensed automatically with the aforementioned feeder units 20.

[0046] The collection section 3 comprises a plurality of collection trays 30 which are held in a circular array, again similar to US 2014 / 0366489 Al, for receiving the discrete medicaments M that are dispensed by the feeder units 20. The array of collection trays 30 is rotatable such that each collection tray 30 moves along all of the feeder positions and is moveable with respect to the feeder units 20 in the dispensing section 2. The (non-shown) valve of a respective one of the plurality of trays 30 is opened when the respective one of the plurality of trays 30 is located above the packaging unit 32 in order to release collected medicaments from the respective one of the plurality of trays 30 into the packaging unit 32.

[0047] The packaging section 6 is configured for receiving the discrete medicaments M collected in the collection section 3 and for packing or packaging said discrete medicaments M in the medicament packages P. In this exemplary embodiment, the medicament packages P are individually closed pockets or pouches formed in a continuous packaging material, in particular a foil F. More specifically, the packaging section 4 can further comprise a foil supply reel for supplying the foil F, a printer unit with a printer head for printing relevant information, such as patient information or medical information, on the foil F and a sealing unit with one or more sealing members for sealing the foil F around the discrete medicaments M. Typically, the foil F is pre-folded such that the discrete medicaments M can be received in the fold. The one or more sealing members subsequently seal the other three sides of the medicament package P.

[0048] In this example, the collection section 3 is located below or vertically under the feeding section 2 and the packaging section 6 is located below or vertically under the collection section 3. The discrete medicaments M are dropped from one section 2, 3, 6 into the next under the influence of gravity.

[0049] The dispensing device 1 can be further provided with a plurality of sensors (not shown) for monitoring the production processes in the dispensing device 1.

[0050] The dispensing system 1 further comprises a control unit 7 that is operatively and / or electrically connected to the feeder units 20, the dispensing section 2, the collection section 3, the packaging section 6 (and packaging units 32), the robotic manipulator 11, and other electronic equipment, such as drives, sensors and the like, for controlling operation of the dispensing system 1. The control unit 7 comprises a special purpose processor 8 and a computer-readable medium 9 holding computer-readable code or instructions that, when executed by the processor 8, can cause the dispensing device 1 to operate according to the methods described in more detail hereafter. The computer-readable medium 9 is non- transitory or tangible, e.g. a physical data carrier such as a hard-drive, a USB-drive, a RAM memory or the like. The dispensing device 1 may further be provided with a graphical user interface 13, for example a screen, to provide a human operator with useful information and / or instructions about the dispensing, collection and packaging operations.

[0051] The overall production process comprises but is not limited to one or more processes of the group comprising: storing of discrete medicaments M, preparation of the discrete medicaments M for dispensing, dispensing of the discrete medicaments M, collecting of the discrete medicaments M, packaging of the discrete medicaments M in the plurality of packages P, discharging of said plurality of packages P from the dispensing device 1 and inspection of the packages P.

[0052] A schematic view of an example of a feeder unit 20 is shown in Fig. 3, with Fig. 4 showing a schematic cross section of the dispensing mechanism 60 of the feeder unit of Fig. 3. The feeder unit 20 comprises a chamber 50 configured for holding a plurality of medicaments, and a container lid 51 that is hingeably connected to the container chamber 50 for opening the top of the container chamber 50 in order to gain access to a filling opening of the container chamber 50, such that the container chamber 50 may be refilled or medicaments within the container chamber 50 may be replaced with other medicaments. The container lid 51 can include a locking latch 52 to enable to the container lid 51 to be locked in the closed position. Additionally, the container lid 51 can be provided with a container grip 53 enabling an operator or the robotic manipulator to grip the feeder unit 20 for handling it.

[0053] The feeder unit 20 comprises a dispensing mechanism 60 arranged below the container chamber 50. As shown in figures 3 and 4, the dispensing mechanism 60 comprises a singulating body 61 with a plurality of singulation chambers 62, each of which is arranged for accommodating two or more of the medicaments M in a single row. The singulating body 61 can comprise a conical top surface 64 for guiding the medicament M in the container chamber 50 towards the singulation chambers 62 which are arranged at the circumference of the singulating body 61. The singulating body 61 comprises a central axis which substantially coincides with the central axis H of the feeder unit 20.

[0054] A first release member 65 is arranged below the singulating body 61, which first release member 65 comprises a release opening 66. The first release member 65 is fixed inside and, therefore, stationary in the feeder unit 20, and the singulating body 61 is rotatable around its central axis in order to subsequently align one of the plurality of singulation chambers 62 with the release opening 66.

[0055] A separating member 67 is arranged above the first release member 65, which separating member 67 comprises a plate or a brush which extends out into the singulation chamber 62 that currently is aligned with the release opening 66. The distance between the separating member 67 and the first release member 65 is substantially equal to the length 1 of a single medicament M when arranged in the singulation chambers 62. The separating member 67 is arranged to allow only the lowermost medicament M directly above the first release member 65 to drop through the release opening 66, such that only one medicament M will fall through the release opening 66. In this example, the medicaments M fall through the release opening 66 vertically or substantially vertically towards, to or into one of the collection trays 30 underneath. Upon rotating the singulating body 61, the respective singulation chamber 62 is freed from the separating member 67, and the medicaments M are allowed to move downwards in the respective singulation chamber 62.

[0056] A storage body 68 can be arranged below the first release member 65, which comprises a plurality of waiting chambers 69, as shown in Figs. 3-4. Each waiting chamber 69 is arranged for receiving and accommodating the medicaments M from one singulation chamber 62. The storage body 68 comprises a central axis which substantially coincides with the central axis h of the feeder unit 20 and is rotatable around its central axis in order to subsequently align one of the plurality of waiting chambers 69 with the release opening 66.

[0057] A second release member 70 is arranged below the storage body 68, which is provided with a dispensing opening 71 for dispensing a medicament out of the feeder unit 20. The second release member 70 is fixed in the feeder unit 20, and the storage body 68 is rotatable with respect to the second release member 70 in order to align one of the plurality of waiting chambers 69 with the dispensing opening 71 to dispense the medicament M from the feeder unit 20. The dispensing opening 71 can be arranged out of alignment with the release opening 66, such that a medicament M that falls into a waiting chamber 69 is detained inside the waiting chamber 69 and thus is not immediately dispensed out of the container 20.

[0058] As shown in figure 4, the feeder unit 20 can comprise a detection arrangement for at least facilitating a detection of whether a medicament M has fallen through the release opening 66 into the waiting chamber 69 below. This detection arrangement comprises a passage 72 for a light beam that crosses the release opening 66 and is arranged directly below the first release member 65 and the storage body 68. The detection arrangement further comprises a light source 73 for emitting a light beam through the passage 72 and a light detector 74 to detect the light beam and thereby the passing of a medicament M through the passage 72 which temporarily blocks the light beam. The light source 73 and light detector 74 are provided with connectors 75 for connecting with positioning columns 21 arranged on each dispensing position for supplying power to the light source 73 and connecting the light detector 74 to the control unit 7.

[0059] As shown in figure 4, the feeder unit 20 can further comprise a further detection arrangement with a second light source 76 for emitting a second light beam which crosses the dispensing opening 71 and a second light detector 77 to detect the second light beam and thereby the passing of a medicament M through the dispensing opening 71 and into a drop tube or opening 22 at the dispensing position.

[0060] Additionally, the feeder unit 20 is provided with an alignment encoder 75, also called position encoder, configured for determining whether one of the plurality of singulation chambers 62 is aligned, preferably fully, with the release opening 66, and operatively connected to the control unit 7. The alignment encoder 75 is calibrated so that encoder steps are indicative for the aligned positions. In this context, the term ‘encoder’ is to be interpreted as a device that converts a motion into an electrical or electronic signal. The alignment encoder 75 may be a rotary encoder or any other type of encoder, for example, a series of holes strategically placed in the feeder unit 20 to allow light to selectively pass to a photocell when the singulation chambers 62 are in position. Alternatively, alignment could be determined through physical position sensing, such as protrusions entering a notch to determine an alignment.

[0061] In addition, the singulating body 61 and / or the storage body 68 are provided with a driving motor (not shown), such as a stepper motor, for driving the rotation of the singulating body 61 and / or the storage body 68 around their central axis H. For example, the rotating speed of the singulating body 61 can be approximately 1.9 rotations per second. The dispensing device may supply power to the driving motor and / or connect the driving motor to the control unit 7. Alternatively, the feeder unit 20 is not provided with a driving motor and an external driving motor for coupling to the singulating body 61 and the storage body 68 is arranged at each dispensing position.

[0062] A method of dispensing a medicament M from one of the feeder units 20 is described below with reference to a single feeder unit 20, but would apply to any of the feeder units 20. First, one or more medicaments M are accommodated into one or more of the plurality of singulation chambers 62 of the singulating body 61. Accommodating medicaments M into the singulation chambers 62 may be understood as allowing the medicaments M to move into the singulation chambers 62 while the singulating body 61 is moving or is standing still.

[0063] Next, the singulating body 61 is moved (rotated) with respect to the first release member 65 into an aligned position in which one of the plurality of singulation chambers 62 is aligned with the release opening 66. Whether the one of the plurality of singulation chambers 62 is aligned with the release opening 66 may be determined or measured by means of the alignment encoder 78 at the feeder unit 20, or other means of determining alignment such as a notch and protrusion arrangement. When it is determined that the one of the plurality of singulation chambers 62 is aligned with the release opening, movement of the singulating body 61 with respect to the first release member 65 is stopped.

[0064] After stopping movement of the singulating body 61 with respect to the first release member 65, the singulating body 61 is typically maintained stationary with respect to the first release member 65, for example, for a predetermined waiting period. For example, the waiting period may be in the range between 40 and 120 milliseconds, in dependence of the size, shape and structure of the medicament to be dispensed. During this predetermined waiting period, the lowermost medicament M within the singulation chamber 62 above the release opening 66 is allowed to fall through the release opening 66. This can be into a waiting chamber 69 of the storage body 68 or into some other configuration, such as a hopper or chute in other embodiments. Simultaneously, further medicaments may move into singulation chambers 62. While the singulating body 61 is maintained stationary with respect to the first release member 65, the detection arrangement can detect whether a medicament passes through the passage 72, though some embodiments may not have such sensing. Alternatively, the movement can be based on actual detection of a medicament moving through, and not simply a predetermined waiting period.

[0065] In operation, the speed of dispensing depends on the speed at which medicaments are fed into the singulation chambers 62, any waiting chambers 69 and out through the dispensing opening 71 / 22. Thus, this relies on the rotation speed of the singulating body 61. The singulating body 61 typically rotates at the fastest speed in which medicaments M reliably enter singulation chambers 62 and move through release opening 66. This speed is typically set for when a feeder unit 20 is full or near full (as shown in Fig. 5A). However, when a feeder unit 20 is getting close to empty, as shown in Fig. 5B, medicaments M can be prone to not feeding into a singulation chamber 62, also called “skipping”, if the singulation body 61 continues to rotate at the same (fast) speed. Thus, the singulation chamber 61 needs to make further rotations to fill the singulation chambers 62 and eventually dispense, slowing down overall operations. Alternatively, in past systems, the rotation speed of singulating body 61 can be set to a lower speed such that skipping is reduced or eliminated. However, that results in less efficient operations overall as the rotation or dispensing speed is lower throughout dispensing operations.

[0066] Method 80, shown and described with respect to Fig. 6, allows for overall more efficient operations while reducing or eliminating skipping (due to low fill levels) in a feeder unit 20 by using different dispensing (singulating body rotation) speeds depending on a fill level of the feeder unit, and optionally refilling the feeder unit one or more times before dispensing until empty.

[0067] Method 80 starts with dispensing tablets from feeder unit 20 at a first speed Si, step 82. This can mean that singulation body 61 is rotated at first speed Si. This can be stepped rotation speed (as described above), or in some embodiments could be a continuous rotation speed.

[0068] Next, in step 84, it is determined that a fill level of feeder unit 20 has met a threshold T. This can be related to the number of tablets left in feeder unit 20 (as determined by a counter), a weight of feeder unit 20 or any other indicator related to how many tablets are still inside container 50 of feeder unit 20. Such a threshold could be, for example, at or near the level of tablets seen in container 50 of Fig. 5B. Threshold T can vary depending on the tablet, feeder unit 20, etc.

[0069] After determining that a threshold has been met, step 86 determines whether step 88 or step 90 will be performed. Step 88 continues to dispense tablets from feeder unit 20, but at a second speed S2. The second speed S2 is different than the first speed Si, and is typically a lower speed, for example, 25% slower. This lower speed dispensing can continue until feeder unit 20 is empty (step 89) or until an ejection threshold is met (step 98). Such an ejection threshold could be related to actual or estimated tablets remaining, and the likelihood of a dispense at each rotation with the specific tablets and the remaining fill level. When the ejection threshold is met, for example, a fill level where a tablet is not reliably dispensed upon a rotation, the feeder unit could be ejected (step 90).

[0070] Alternatively, step 90 could be performed without first dispensing at second speed S2, ejecting feeder unit 20 from the tablet dispensing device 1 when the threshold is met. After ejection, step 92 can be performed to refill feeder unit 20 such that it is full or at least above the threshold T. After refilling, feeder unit 20 can be reinserted back into tablet dispensing device 1 (step 94), and eventually (or immediately) tablet dispensing device 1 could resume dispensing from feeder unit 20 at first speed Si. These steps could be performed a number of times before step 88 of dispensing from feeder unit 20 at speed S2 until empty is performed. For example, feeder unit 20 could be ejected and refilled 1-10 times when it met the threshold T before going to step 88 of fully emptying at speed S2.

[0071] In parallel, in some methods, while ejecting feeder unit 20, dispensing unit 1 can continue dispensing from a second feeder unit 20’ (with the same type of tablets), shown in dashed process line 96 leading back to step 82 indicating the process for second feeder unit 20’. The dispensing can be at the first speed Si (presuming that the second feeder unit 20’ unit is above the threshold T), and then go through a similar process when a fill level of second feeder unit 20’ meets threshold T.

[0072] To determine which branch is selected in step 86, control unit 7 can examine one or more inputs including but not limited to: how many times feeder unit 20 has been refilled, an expiry date of the remaining tablets in feeder unit 20, the open air time of the oldest tablets in feeder unit 20 (since it had been dispensed to empty), a consumption date of the pouch into which the tablets will be packaged; and a lot number of the tablets (some regulations require that you can only refill non-empty feeder units 20 with tablets of the same lot). In addition, the system could consider parts of the methods disclosed in PCT / NL2022 / 050022, filed 19 January 2022, the contents of which is hereby incorporated by reference, which provides for selecting between a complete empty detection mode and a shortened empty detection mode based on whether a medicament is fed from the container after rotating the dispensing mechanism. In such a system, the cannister can be simply ejected before it is empty (but at least below a threshold) to promote efficient overall dispensing when it is likely there is skipping due to being almost empty and not due to other dispensing problems.

[0073] In some embodiments, method 80 could include a full threshold T2, which could be associated with a third dispensing speed S3. For example, the full threshold T2 could be associated with a very full cannister requiring the third dispensing speed S3, and the threshold T could be associated with an almost empty cannister (where skipping could occur). Thus, when it is determined that a fill level is above the full threshold T2, speed S3 is used for dispensing, and after the full threshold T2 is met, the speed Si (e.g., higher than speed S3) is used for dispensing. Then, when the fill level gets below threshold T, speed S2(e.g., the slowest speed) could be used to reduce or eliminate skipping in an almost empty cannister.

[0074] Thus, in a specific example, control unit 7, at steps 84, 86, can determine that: feeder unit 20 has met threshold T ;

[0075] - there are remaining tablets from the same lot as the remaining tablets in feeder unit 20; and

[0076] - the current or upcoming job requires more of the same type of tablets for completion.

[0077] After determining these things, control unit 7 could then send a signal to eject feeder unit 20 (step M), and provide instructions that feeder unit 20 should be refilled with the tablets from the same lot (step 92); and reinserted into dispensing device 1 (step 94) for further dispensing at speed Si (step 82). In the meantime, dispensing device 1 could dispense tablets from a second feeder unit 20’ (step 82) filled with the same type of tables until a fill level of second feeder unit 20’ met threshold T (step 84), at which point feeder unit 20’ could be ejected (step M) for a similar process; and dispensing device 1 would move to dispensing from refilled (and reinserted) feeder unit 20 at speed Si (step 82).

[0078] Such a process could continue until control unit 7 determined that there were, for example, no more remaining tablets from the same lot for refilling feeder units 20, and thus step 88 should be taken when the currently dispensing feeder unit 20, 20’ met threshold T. Thus, control unit 7 would then send a signal when the threshold T was determined to be met which caused feeder unit 20 / 20’ to dispense tablets (e.g., rotate singulation chamber 61) at a second, slower speed S2 until feeder unit 20 / 20’ was completely empty.

[0079] Thus, using method 80, dispensing device 1 is able to remain dispensing at higher speed Si for much longer (and for more medicaments M) than if each feeder unit 20, 20’ dispensed until empty upon every refill, thereby providing for overall faster dispensing speed Si for much longer periods of time and for dispensing many more tablets at such higher dispensing speeds Si. By only periodically or occasionally dispensing until empty, and / or only slowing down to speed S2 after a number of times refilling the feeder units, dispensing device 1 is able to dispense in an overall more efficient manner. Method 80 is generally performed by control unit 7, though could involve other components, such as remote computers, processors, memory storage devices, etc.

[0080] In summary, the methods and systems / devices described allow for more efficient dispensing of medicaments M by controlling the dispensing speed (e.g., or singulation chamber 61 rotation speed) such that it is associated with a fill level of a feeder unit. When the feeder unit is more full, the speed can be faster, and when the feeder unit fill level gets closer to empty and is more prone to skipping, the dispensing or rotation speed can be slower for a short period of time (e.g., until an ejection threshold or until fully empty) to reduce or eliminate skipping and the additional delays from that. Thus, by using different dispensing or rotation speeds depending on a fill level of the feeder unit, overall dispensing can be more efficient, only using the slower dispensing speeds when needed, for short periods of time. Additionally, by ejecting for refilling one or more times between fully emptying a feeder unit, dispensing device 1 can continue to dispense at higher speeds and dispense more medicaments at higher speeds before needing to slow down for dispensing a feeder until empty. Such a process results in more efficient overall operations, being able to reliably dispense more tablets for packaging into pouches more quickly.

[0081] 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 and packaging. 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 method of selective emptying of a feeder unit in a dispensing device, the method comprising: a) dispensing tablets from the feeder unit at a first speed (Si); and b) when a fill level of the feeder unit meets a threshold, performing one of: bl) dispensing tablets from the feeder unit at a second speed (S2), wherein the second speed (S2) is different than the first speed (Si); or b2) ejecting the feeder unit from the dispensing device.

2. The method of claim 1, wherein the second speed (S2) is slower than the first speed (Si).

3. The method of claim 1, wherein step bl) comprises dispensing tablets from the feeder unit at the second speed (S2) until the feeder unit is empty.

4. The method of any of claims 1-2, wherein step bl) comprises dispensing tablets from the feeder unit at the second speed (S2) until the feeder unit meets an ejection threshold; and then ejecting the feeder unit from the dispensing device.

5. The method of any of claims 1-3, and further comprising the step of: when a fill level of the feeder unit meets a full threshold, dispensing tablets from the feeder unit at a third speed (S3) until the full threshold is crossed, wherein the third speed (S3) is different than the second speed (S2) and the first speed (Si).

6. The method of claim 5, wherein the full threshold is associated with a very full feeder unit and the threshold is associated with an almost empty feeder unit, and wherein the first speed (Si) is greater than the second speed (S2) and the third speed (S3).

7. The method of claim 6, wherein the third speed (S3) is greater than the second speed (S2) and the dispensing of tablets at the second speed (S2)is until the feeder unit is empty.

8. The method of claim 1, wherein when a fill level of the feeder unit meets a threshold and the feeder unit is ejected from the device, the method further comprises: dispensing from a second feeder unit.

9. The method of claim 8, wherein the dispensing from the second feeder unit is at the first speed if a fill level of the second feeder unit is above the threshold.

10. The method of any of the preceding claims, wherein when a fill level of the feeder unit meets a threshold and the feeder unit is ejected for refilling, the method further comprises: c) refilling the feeder unit; d) inserting the refilled feeder unit back into the tablet dispensing device; and e) dispensing tablets from the feeder unit.

11. The method of claim 10, wherein step e) comprises dispensing tablets from the feeder unit at the first speed.

12. The method of any of claims 10-11, wherein steps b), b2), c), d) and e) are performed a set number of times before step bl) is performed.

13. The method of claim 12, wherein the set number of times is related to one or more of: an expiry date of the tablets, a pouch consumption date; and a lot number of the tablets.

14. The method of any of the preceding claims, wherein the first speed and second speed are related to a rotation speed of a singulating body.

15. Dispensing system accommodating one or more feeder units, wherein the dispensing system is arranged for selectively dispensing an amount of discrete medicaments from the one or more feeder units, the system comprising: a dispensing device provided with an array of dispensing positions, wherein the dispensing device at each of said array of dispensing positions is provided with a holder for one of the feeder units and with a through opening for passing discharged medicaments there through, and a control unit for controlling the working of the system and the one or more feeder units arranged on the dispensing device, wherein the control unit is configured to cause at least one of the one or more feeder units to: a) dispense tablets from the feeder unit at a first speed (Si); and b) when a fill level of the feeder unit meets a threshold, perform one of the following: bl) dispense tablets from the feeder unit at a second speed (S2), wherein the second speed (S2) is different than the first speed (Si); or b2) eject the feeder unit from the dispensing system.

16. The dispensing system of claim 15, and further comprising a collection device arranged below the dispensing device, wherein the collection device and the dispensing device are movable with respect to each other, wherein the collection device is provided with a number of collection trays, wherein each of the trays comprises a receiving opening at a side facing the dispensing device for receiving discharged medicaments and each comprises an output.

17. The dispensing system according to claim 16, and further comprising a packaging unit for collecting the received medicaments from the output of a tray and packaging the medicaments.

18. The dispensing system according to any of claims 15-17, wherein the second speed (S2) is slower than the first speed (Si).

19. The dispensing system of any of claims 15-18, wherein the control unit is further configured to control, in step bl), the feeder unit to dispense tablets from the feeder unit at the second speed (S2) until the feeder unit is empty.

20. The dispensing system of any of claims 15-18, wherein the control unit is further configured to control, in step bl), the feeder unit to dispense tablets from the feeder unit at the second speed (S2) until the feeder unit meets an empty threshold, and then eject the feeder unit.

21. The dispensing system of any of claims 15-20, wherein the control unit is further configured to control the system to, when a fill level of the feeder unit meets a full threshold, dispense tablets from the feeder unit at a third speed (S3) until the full threshold is crossed, wherein the third speed (S3) is different than the second speed (S2) and the first speed (Si), preferably wherein the full threshold is associated with a very full feeder unit and the threshold is associated with an almost empty feeder unit, and wherein the first speed (Si) is greater than the second speed (S2) and the third speed (S3), more preferably, wherein the third speed (Ssjis greater than the second speed (S2) and the dispensing of tablets at the second speed (S2) is until the feeder unit is empty.

22. The dispensing system of any of claims 15-21, wherein the control unit is further configured to, when a fill level of the feeder unit meets a threshold and the feeder unit is ejected from the system, control the system to: dispense from a second feeder unit.

23. The dispensing system of claim 22, wherein the control unit is configured to control the dispensing from the second feeder unit to be at the first speed if a fill level of the second feeder unit is above the threshold.

24. The dispensing system of any of claims 15-23, wherein the control unit is configured to, when a fill level of the feeder unit meets a threshold and the feeder unit is ejected for refilling, cause the system to provide instructions for: c) refilling the feeder unit;d) inserting the refilled feeder unit back into the tablet dispensing device; and e) dispensing tablets from the refilled feeder unit.

25. The dispensing system of claim 24, wherein step e) comprises dispensing tablets from the feeder unit at the first speed.

26. The dispensing system of any of claims 24-25, wherein the control unit controls the system to perform steps b), b2), c), d) and e) a set number of times before step bl) is performed.

27. The dispensing system of claim 26, wherein the set number of times is related to one or more of an expiry date of the tablets, a pouch consumption date; and a lot number of the tablets.

28. The dispensing system of any of claims 15-27, wherein the feeder unit comprises a rotatable singulating body, and wherein the dispensing speed relates to the rotation speed of the singulating body.

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