Mass Flow Conveyor Table for Pharmacy Vial Distribution
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Solution Overview
Problem
Automated dispensing systems in mail order pharmacies face inefficiencies in processing and routing prescription vials, leading to increased travel and processing times, particularly when handling multi-prescription orders, due to the need for complex control systems and diversion mechanisms in single-file conveyor systems.
Innovation Solution
Implementing mass flow conveyor tables with stacked outbound lanes and RFID-tagged pucks to manage vial movement in a mass flow configuration, reducing the reliance on complex control systems and sensors, and using plastic guide members to direct vials to available lanes for balanced distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single-file conveyor systems with complex control systems and sensors are used to route and divert vials, then vials can be routed to appropriate destinations, but vial travel and processing time increases
Solution Approach 1:
The patent removes complex control systems, sensors, and active diversion mechanisms from the conveyor system. Instead of using active control elements to route vials, the system extracts these components entirely and replaces them with a passive mass flow approach where vials are distributed through stacked outbound lanes without individual routing control.
Solution Approach 2:
The system allows vials to self-route through the mass flow conveyor tables and stacked outbound lanes without external control intervention. Vials naturally flow into available lanes based on their physical movement through the system, eliminating the need for active routing decisions by control systems.
2Adaptability or versatility
If group processing of vials is implemented to process multi-prescription orders together, then all vials for an order can be packaged together, but vial processing time and system complexity increases
Solution Approach 1:
The patent segments the outbound lanes into multiple stacked lanes that can independently accept and transport vials. This segmentation allows vials from the same order to be distributed across different lanes simultaneously, enabling group processing without requiring all vials to travel together as a single group through the entire system.
Solution Approach 2:
The system adds a vertical dimension by implementing stacked outbound lanes (multiple layers) instead of a single-plane conveyor system. This dimensional change allows parallel processing of vials across multiple levels, increasing throughput capacity while maintaining the ability to handle multi-prescription orders efficiently.
3Ease of operation
If multiple sorting stations and diversion mechanisms are deployed to handle vial routing, then vials can be sorted to appropriate stations, but device complexity and processing time increases
Solution Approach 1:
The mass flow conveyor tables and stacked outbound lanes serve multiple functions simultaneously: they transport vials, distribute them to different destinations, and enable group processing of multi-prescription orders. This universal structure replaces the need for separate sorting stations and diversion mechanisms at different locations.
Solution Approach 2:
The patent merges the functions of multiple sorting stations and diversion mechanisms into a single integrated mass flow conveyor system with stacked lanes. Instead of having separate entities for routing and sorting, these functions are combined into one continuous flow system where distribution occurs naturally through the lane structure.
Data Source
AI summary
An automated method and system for distributing prescription vials from upstream locations of a pharmacy to various downstream destinations using a stacked configuration of outbound lanes so that vials will enter the first outbound lane that is not blocked. The distribution table of the present invention has a lower portion having outbound lanes and an upper portion having outbound lanes and where the table is adapted to move vials in a loop pattern around the lower and upper portions.