Vibratory Tablet Feeder with Optical Size Classification
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Solution Overview
Problem
Existing optical counters for pharmaceutical tablets and capsules are not highly accurate due to mechanical feed system failures, which cause 'bunching' issues, requiring complex setups and skilled operators, and lack sophisticated sensing and control systems.
Innovation Solution
A vibratory counting and dispensing apparatus with a feed hopper, linear feeder, and a spiral ramped feed bowl, controlled by electrically-controlled vibrators and an optical system for singulated flow and size classification, using a controller to adjust vibration amplitude based on tablet size and count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple optical sensor system is used for counting tablets, then the device complexity is reduced, but the counting accuracy deteriorates due to bunching issues
Solution Approach 1:
The patent applies mechanical vibration through a vibratory feed system that oscillates at controlled frequencies to singulate tablets before they reach the optical sensor. This vibration prevents multiple tablets from arriving simultaneously at the sensor, eliminating bunching errors while maintaining system simplicity.
Solution Approach 2:
The system employs periodic action by controlling the vibratory feeder to operate in synchronized cycles with the optical sensor detection rate. This coordination ensures that tablets are presented to the sensor one at a time at regular intervals, improving counting accuracy without requiring complex continuous control mechanisms.
2Measurement precision
If stringent demands are placed on the feed system to achieve accurate counts, then the counting accuracy is improved, but the device complexity and operational difficulty increase
Solution Approach 1:
The vibratory feed system is designed to self-regulate tablet flow through its inherent vibration characteristics. The system automatically adjusts to maintain singulated flow without requiring external intervention or complex control mechanisms, achieving accurate counts while minimizing operational complexity.
Solution Approach 2:
The system achieves accurate counting by optimizing vibration frequency and amplitude parameters of the feed system. By carefully selecting and maintaining these parameters within specific ranges, the system ensures consistent single-file tablet flow without requiring complex adaptive control mechanisms.
3Measurement precision
If mechanical feed systems are designed to produce single-file flow, then the counting accuracy is improved, but the ease of operation deteriorates due to skilled operator requirements
Solution Approach 1:
The patent replaces complex mechanical adjustment mechanisms with an electrically controlled vibratory system. This substitution eliminates the need for manual mechanical adjustments by skilled operators, as the vibration-based feed system automatically maintains proper tablet flow without requiring operator intervention.
Solution Approach 2:
The vibratory feed system is designed to handle various tablet types and sizes through a single unified mechanism. The system's vibration-based approach universally accommodates different pharmaceutical products without requiring operator-reconfigurable mechanical components, significantly improving ease of operation.
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
Achieves accurate counting and dispensing of tablets by ensuring a singulated flow and adjusting vibration amplitude dynamically, improving accuracy and reducing operator skill requirements.
Implementation Method 1
The feed bowl is vibrated by one or more electrically-controlled feed bowl vibrators in a manner that causes a plurality of tablets stored in the feed bowl to move as a singulated flow of tablets to the exit opening
Implementation Method 2
A feeder vibrator is configured to vibrate a linear feeder such that tablets stored in the feed hopper are conveyed via the linear feeder to a feed bowl
Implementation Method 3
The singulated flow of tablets pass through the exit opening of the feed bowl for supply to an optical system. The singulated flow of tablets is counted by the optical system
Data Source
AI summary
An apparatus for counting and dispensing tablets includes a vibratory tablet feeder for feeding tablets to be counted to an output opening, at least one electrically-controlled vibrator coupled to the tablet feeder for vibrating the tablet feeder such that a singulated flow of tablets exits the output opening, and an optical system including at least one light source and at least one detector array located about a channel disposed downstream from the output opening of the tablet feeder. The optical system is configured to count tablets that pass through the channel as well as determine a tablet size class for the tablets that pass through the channel. Operation of the at least one electrically-controlled vibrator is controlled based on the tablet size class determined by the optical system.