Automated Pill Loading System with Illumination Guidance
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Solution Overview
Problem
The existing methods for preparing sets of individual pill containers are time-consuming and prone to human errors due to the manual filling of varying quantities and types of medication into each pocket, especially for long-duration prescriptions.
Innovation Solution
A system comprising a support with apertures and illumination indicators, an enclosure with drawers and illumination, and an item transfer system using vacuum and LED indicators to guide the placement of items into the container-defining sheet, facilitated by a controller and manipulator system for efficient and accurate loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual filling of pill containers is used, then flexibility in handling varying quantities and types of medication is maintained, but the process becomes time-consuming and prone to human errors
Solution Approach 1:
The system enables self-service through automated mechanisms where the filling device automatically loads items into containers without requiring manual intervention for each placement, thereby maintaining operational flexibility while significantly reducing the time required to complete the filling process
Solution Approach 2:
The patent replaces manual mechanical filling operations with an automated mechanical system that uses conveyors, positioning mechanisms, and automated loading devices to transfer items into containers, eliminating human errors and reducing processing time while maintaining the ability to handle varying quantities and types of items
2Adaptability or versatility
If manual filling of pill containers is used, then adaptability to different medication configurations is maintained, but human errors in placing incorrect tablets increase
Solution Approach 1:
The system incorporates feedback mechanisms such as sensors and detection devices that verify the correct placement of items in containers, providing real-time confirmation and allowing for immediate correction of any placement errors, thereby ensuring high reliability while maintaining adaptability to different medication configurations
Solution Approach 2:
Manual placement operations are replaced with automated positioning and loading mechanisms that use precise mechanical control, computer coordination, and verification systems to ensure accurate placement of the correct items in the correct containers, eliminating human errors while maintaining versatility
3Productivity
If automated filling system is implemented, then filling speed and accuracy are improved, but system complexity increases
Solution Approach 1:
The automated filling system is divided into separate functional modules including item storage compartments, conveyance mechanisms, positioning devices, loading mechanisms, and verification systems. This segmentation allows each component to perform its specific function efficiently while simplifying the overall system design and maintenance, achieving high productivity without excessive complexity
Solution Approach 2:
The system employs universal components and mechanisms that can handle multiple types of items and container configurations through programmable control, reducing the need for specialized equipment for each task and thereby minimizing overall system complexity while maintaining high filling speed and accuracy
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces the time and errors associated with filling pill containers by providing guided illumination and automation for precise placement of items, enhancing efficiency and accuracy in loading the containers.
Implementation Method 1
A vacuum supply for generating suction; a manifold mounted about the handle and in fluid engagement with the vacuum supply for receiving suction
Data Source
AI summary
A system for loading items into a container-defining sheet. The system includes a support for receiving the container-defining sheet, the support having a top surface provided with a number of apertures equal to the number of cavities embossed in the container-defining sheet. A support illumination board is positioned on a back portion of the support. The illumination board includes a plurality of evenly-spaced-apart support light indicators, each support light indicator being positioned substantially centrally with respect to a corresponding aperture of the support and adapted to back-illuminate one of the containers of the container-defining sheet upon placement of the container-defining sheet into the support. An illumination board controller controls operation of the support light indicators to indicate into which container of the container-defining sheet each item is to be loaded. An enclosure includes drawers holding items to be put into the container-defining sheet.