Mass Flow Vial Feed System for Pharmacy Automation
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Solution Overview
Problem
Traditional automated dispensing systems for mail order pharmacies face inefficiencies in transporting and routing vials, requiring complex control systems and numerous sensors to manage single-file conveyor lanes, which can lead to bottlenecks and increased human intervention.
Innovation Solution
The implementation of mass flow conveyor tables at predetermined points in the system allows vials to move in a mass flow rather than a single-file line, reducing the need for complex control systems and sensors, and incorporating feedback control mechanisms to regulate vial delivery and distribution, thereby eliminating the need for frequent lane switching and diversion mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single-file conveyor lanes are used to transport vials, then precise control and routing of individual vials is achieved, but device complexity and number of sensors increase
Solution Approach 1:
A mass flow table serves as an intermediary device between the conveyor lane and the destination. The table receives vials from the conveyor and uses gravity and mass flow dynamics to distribute them to multiple outbound lanes without requiring sensors or active control for each individual vial routing decision.
Solution Approach 2:
The mass flow table enables vials to self-route to appropriate destinations through their own motion and the table's geometry. Vials naturally flow into available outbound lanes based on their trajectory and the table's configuration, eliminating the need for external control systems to direct each vial.
2Loss of information
If single-file conveyor lanes are used, then individual vial tracking is maintained, but productivity and throughput are reduced
Solution Approach 1:
The system segments the vial flow into groups that can be processed in parallel. The mass flow table divides the single-file input into multiple outbound streams, allowing simultaneous processing of multiple vials across different lanes, thereby increasing throughput while maintaining individual vial tracking through RFID tags.
Solution Approach 2:
The system transitions from one-dimensional single-file conveyor transport to two-dimensional mass flow table distribution. This dimensional change allows multiple vials to be processed simultaneously across different spatial paths while maintaining individual identification through RFID tracking.
3Manufacturing precision
If complex control systems with multiple sensors are implemented, then vial distribution accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The mass flow table acts as a passive intermediary that uses gravity and fluid dynamics to achieve accurate vial distribution without active control. The table's geometry and flow characteristics naturally guide vials to appropriate destinations, replacing complex sensor-based control systems.
Solution Approach 2:
The system replaces active mechanical control systems (motors, sensors, actuators) with passive physical principles (gravity, mass flow, fluid dynamics). The mass flow table uses these natural forces to achieve accurate distribution, eliminating the need for complex electronic control and sensing infrastructure.
Data Source
AI summary
An automated vial feed system for an automated prescription filling system. The system has a plurality of sensors located above a vial distribution table for controlling the pace of vial delivery to the table. The sensors determine the load of vials on the table and a control system uses the information as feedback to the vial delivery system.