[0001] The present invention relates to an automated blister pack pill dispenser and particularly
but not exclusively relates to a dispenser capable of dispensing pills from blister
packs of varying shapes and sizes and having blister pockets of varying shapes and
sizes.
[0002] Pills are often packaged in a blister pack comprising a base provided with a plurality
of pill pockets in which the pills are held, and a foil sheet that closes the pill
pockets. To access the pills, either the foil sheet has to be removed, or more typically,
the pills are forced through the foil sheet by applying pressure to the pill pockets.
The blister pack base is typically of a plastics material, whilst the foil may be
a metal or plastic membrane.
[0003] It is sometimes desirable, or even a requirement, that a number of pills are dispensed
from a blister pack and then repackaged. For example, nursing homes and care homes
often require pills to be repackaged into specialised packaging particular to a particular
patient, dosage or to conform to a maximum amount of a particular pill the home is
legally allowed to keep. It is a problem to rapidly, efficiently and accurately dispense
multiple pills from a blister pack or packs.
[0004] Furthermore, blister packs can take a wide variety of shapes and sizes and are used
for pills of a wide variety of shapes and sizes. Thus the length, width and depth
of the blister packs may vary considerably, as may the length, width and depth of
the blister pockets. Generally the blister pockets are arranged in parallel, straight
rows, but the length and transverse spacing of the rows can vary, as can the longitudinal
spacing of blister pockets in each row.
[0005] We have proposed, in our UK patent
GB 2383988 B, a blister pack pill dispenser comprising an electronically actuated plunger that
forces a pill from a blister pocket when the pocket is placed in a locating slot beneath
the plunger by a dispenser operator. The present invention stems from some work in
trying to provide an even more efficient electronically actuated pill dispenser.
[0006] According to a first aspect of the invention there is provided an automated blister
pack pill dispenser comprising a blister pack loader operative to receive a blister
pack and load the blister pack onto a platform, and at least one blister pack sensor
operative to sense the blister pack on the platform and to generate at least one blister
pack signal indicative of the transverse and longitudinal positions of the pills on
the blister pack relative to a datum, the dispenser further comprising a pill dispensing
head comprising a plunger driven by an electrically powered plunger actuator, and
a pill dispensing plate comprising at least one aperture located beneath the plunger,
the plate being configured to at least partially support the blister pack, at least
one motor being provided to enable relative movement between the pill dispensing head
and the platform in directions transverse and longitudinal to the datum, an electronic
controller being provided operative to receive the blister pack signal and to process
the blister pack signal to control the motor such that the relative transverse position
and the relative longitudinal position between the pill dispensing head and the datum
are arranged such that a pill pocket of the blister pack is transversely and longitudinally
aligned with the plunger, the controller being further operative to subsequently activate
the plunger activator to drive the plunger to push a pill from the aligned blister
pack pocket, the dispensed pill dropping through the aperture in the pill dispensing
plate.
[0007] The pill dispensing head may be mounted on one end of a cantilevered transversely
extending arm, the other end of the transverse arm being mounted on the dispenser.
[0008] The pill dispensing head may be mounted on a carriage movably mounted on a track
on the dispenser.
[0009] Preferably the loader comprises a chute having at least one movable side to enable
the width of the loader to be adjustable.
[0010] Preferably the chute is inclined relative to the platform.
[0011] Preferably the platform is provided with at least one side guide against which a
margin of the blister pack abuts in use.
[0012] Preferably the side guide is movably mounted on the dispenser such that the transverse
position of the side guide can be altered so as to enable the width of the platform
to be adjustable.
[0013] The blister pack sensor may further comprise a width detector operative to generate
a width signal indicative of the width, that is, the transverse dimension, of a blister
pack.
[0014] Preferably the controller is operative to receive and process the width signal, to
automatically adjust the transverse position of the movable loader, the side of the
movable side guide of the platform and the pill dispensing head to correspond to the
width of the blister pack.
[0015] Preferably the blister pack sensor comprises a blister pack sensor camera. More than
one camera may be used.
[0016] Preferably the width detector comprises a width detector camera.
[0017] The camera may include an illuminator to illuminate an area detected by the camera.
[0018] Preferably the loader is provided with a blister pack indexing mechanism operative
to index one blister pack at a time from the loader onto the platform.
[0019] Preferably the indexing mechanism comprises upper and lower retractable pins, the
pins being movable from a projecting position in which they project into the chute
to support a blister pack in the chute, to a retracted position in which the blister
pack can drop down the chute, the upper and lower pins being controlled by the controller
to sequentially project and retract such that one blister pack at a time drops down
the chute.
[0020] Preferably the platform comprises a conveyor operative to convey the blister pack
from the loader to the pill dispensing head.
[0021] Preferably the conveyor comprises a conveyor belt.
[0022] Preferably the controller is operative to control the conveyor, when a blister pack
is on the conveyor, to index adjacent blister pockets of the blister pack to a position
longitudinally aligned with the plunger.
[0023] Preferably the conveyor comprises an inlet and an outlet conveyor, longitudinally
opposed on each side of the plate.
[0024] Preferably a pill retaining tray is provided beneath the pill dispensing plate to
retain pills that drop through the aperture.
[0025] Preferably a dispensed pill receptacle is provided to receive dispensed pills from
the pill retaining tray.
[0026] Preferably the dispensed pill container comprises an electronic identifier such as
a bar code or RFID chip for example.
[0027] Preferably the pill dispensing plate is movable with the pill dispensing head.
[0028] The dispenser may be provided with a plurality of plates each provided with differently
shaped and/or differently sized apertures.
[0029] A single plate may be provided comprising a plurality of differently shaped and/or
differently sized apertures, the plate being movably mounted on the dispenser such
that a selected aperture can be aligned with the plunger, a plate motor being provided
to move the plate in response to a plate control signal from the controller, the plate
control signal being generated in dependence upon the size and shape of blister pocket
detected by the blister pack sensor such that the selected aperture corresponds to
the detected blister pocket.
[0030] The, some or each aperture may comprise a cut-out portion cut away from a side margin
of the plate.
[0031] Preferably the controller includes a touch screen.
[0032] Preferably the controller stores data relating to the pill or pills dispensed.
[0033] According to a second aspect of the invention there is provided a dispenser assembly
comprising a dispenser according to the first aspect of the invention mounted on a
dispenser desk.
[0034] The dispenser desk may comprise a trolley provided with wheels to enable the desk
and dispenser to be moved.
[0035] Other aspects of the present invention may include any combination of the features
or limitations referred to herein.
[0036] The present invention may be carried into practice in various ways, but embodiments
will now be described by way of example only with reference to the accompanying drawings
in which:
Figure 1 is an enlarged perspective view of a dispenser in accordance with the present invention;
Figure 2 is a perspective view of the dispenser of Figure 1 mounted on a dispenser trolley;
Figures 3a to 3d are schematic front views of a loader mechanism comprising part of the dispenser
of Figures 1 and 2, in different conditions; and
Figures 4a to 4d are enlarged plan views of different examples of a dispensing plate comprising part
of the dispenser of Figures 1 and 2.
[0037] Referring to the Figures, an automated blister pack pill dispenser 1 is mounted on
a dispenser desk comprising a wheeled trolley 3.
[0038] The dispenser 1 comprises an oblong base frame 5 at one end of which is mounted a
blister pack measuring table 7 and a blister pack width sensor in the form of a first
camera 9, the width sensor comprising part of a blister pack sensor.
[0039] A blister pack loader 11 is mounted on the base frame 5 adjacent the measuring table
7 and comprises an inclined chute the front of which is open, and the opposed sides
13, 14 of which are provided with respective indexing mechanisms 15 operative to index
a stack of blister packs sequentially down the chute 11. The side 14 of the chute
11 is movably mounted on a transversely movable chassis 16 such that the relative
transverse spacing between the sides 13, 14 can be adjusted by a suitable motor 18
to accommodate the desired width of blister pack.
[0040] The transversely movable chassis 16 extends along the length of the base frame 5
and is movably mounted thereon via suitable carriages 20 and tracks 22.
[0041] A platform comprising an input conveyor in the form of conveyor belt 17 is located
beneath the lowermost end of the chute 11 and extends longitudinally along the base
frame 5 away from the chute 11. The conveyor belt 17 passes beneath a pill pocket
sensor in the form of a second camera 19 that comprises part of the blister pack sensor.
Elongate guides are provided at the transversely opposed sides of the conveyor belt
17 and comprise an outer fixed guide 21, and a transversely movable inner guide 23
that can be moved towards and away from the longitudinal axis of the conveyor belt
17 to vary the width of the conveyor belt to accommodate the desired width of blister
pack. The inner guide 23 is mounted on the chassis 16.
[0042] A pill dispensing head, shown generally at 25, is also movably mounted on the base
frame 5 at the end of the conveyor belt 17 distal from the chute 11.
[0043] The head 25 is transversely movably mounted on the base frame 5 such that it can
be moved towards or away from the longitudinal axis of the conveyor belt 17 so as
to alter the relative transverse position of the head 25 and the conveyor belt 17.
A motor 27 generates the required transverse movement.
[0044] The head 25 comprises a transversely extending support arm 29, one end of which may
be mounted on the chassis 16, or on a separate mount/carriage independently movable
from the chassis 16.
[0045] The other end of the arm 29 is provided with an electronically controllable moving
coil plunger actuator 31 connected to a pill dispensing plunger 33, the longitudinal
axis of the plunger 33 being inclined to the vertical and to the plane of the conveyor
belt 17.
[0046] A pill dispensing plate 35 is provided on the head 25 beneath the plunger 33, the
upper planar surface of the plate 35 being substantially flush with the plane of the
upper surface of the conveyor belt 17. The plate 35 is provided with an aperture 37
directly below the tip of the plunger 33.
[0047] A pill tray 39 is mounted on the head 25 beneath the plate 35 and is in communication
with a pill receptacle 41.
[0048] An outlet conveyor in the form of conveyor belt 43 is provided on the other side
of plate 35 from inlet conveyor belt 17 so as to be longitudinally opposed thereto.
The conveyor belt 43 again comprises a fixed outer guide 45 and a transversely movable
inner guide 47 that is movable towards and away from the longitudinal axis of the
belt 43, the movable guide 47 being mounted on the chassis 16. The end of the second
belt 43 distal from the plate 35 is adjacent a waste receptacle 49. The dispenser
1 further comprises an electronic controller 51 which in this example comprises at
least one microprocessor and a touchscreen 53. The controller 51 is operative to receive
signals from the first and second cameras 9, 19, and to control the loader 11, the
first and second conveyor belts 17, 43, the adjustable guides 23, 47, the transversely
movable chassis 16, the transverse position of the dispensing head 25, and the actuation
of the plunger 33.
[0049] With particular reference to Figure 3, each indexing mechanism 15 of the loader 11
comprises upper and lower retractable pins 55, 57 that are spaced apart on the inside
of each side 13, 14 of the chute. The pins 55, 57 can be moved from a projecting position
in which the pins 55, 57 project into the chute, to a retracted position in which
the tips of the pins 55, 57 do not substantially project into the chute. The movement
of the pins 55, 57 is controlled by the controller 51 via suitable electromagnetic
mechanisms such as solenoids, or via hydraulic or pneumatic valves and pipework (not
shown).
[0050] The controller 51 is operative to control the upper pair of pins 55 separately from
the lower pair of pins 57. In use, a stack of blister packs are placed in the chute
of the loader 11 with the foil 63 of the lowermost pack 61 resting on the upper pair
of pins 55, the upper pins 55 at this stage projecting into the chute. The pins 55,
57 are controlled to index the blister packs down the chute and onto the first conveyor
belt 17, one blister pack at a time. Thus, the upper set of pins 55 are retracted
such that lowermost blister pack 61 drops onto the lower set of pins 57. The upper
set of pins 55 is then extended so as to project into the chute and support the next
blister pack 65. The lower set of pins 57 are then retracted so that the first blister
pack 61 drops out of the chute and onto the first conveyor belt 17. The lower set
of pins 57 is subsequently extended and the process is repeated at the required time,
as controlled and determined by the controller 51.
[0051] In use of the dispenser 1, a blister pack is initially placed on the measuring table
7. The width, or transverse dimension, of the blister pack is measured using the first
camera 9. The first camera 9 generates a width signal indicative of the shortest dimension
of the blister pack. This width signal is received and processed by the controller
51 which then generates a width adjustment signal used to control a motor or motors
18 to adjust the transverse position of the chute side wall 14, the inner conveyor
guides 23, 47, and the dispensing head 25. Thus, before the blister pack reaches the
loader 11, the transverse position of all of the necessary components of the dispenser
1 are adjusted to correspond to the measured width of the blister pack in question.
[0052] The blister packs corresponding to the measured blister pack are then placed in a
stack in the chute of the loader 11, the foil of the lowermost blister pack resting
on the upper pins 55 of the indexing mechanisms 15.
[0053] The indexing mechanisms 15 are controlled as described above such that the lowermost
blister pack drops onto the first conveyor belt 17. The conveyor belt 17 may already
be activated, or may be activated when the blister pack is dropped onto it, and transfers
the blister pack towards the dispensing head 25, the blister pack being guided and
prevented from skewing or falling from the belt 17 by side guides 21,23.
[0054] Before the blister pack reaches the dispensing head 25, properties of the blister
pack are measured using second camera 19. The measurements include some or all of
the width and length of the blister pack, the diameter of pill pocket, the shape of
pill pocket, the number of pill pockets, the longitudinal spacing between pill pockets,
and the transverse spacing between pill pockets. The measurements made by the second
camera 19 are sufficient to first generate a signal indicative of the required relative
transverse position of the dispensing head 25 for the plunger 33 to be aligned with
a row of pockets on the blister pack, and to secondly generate a signal indicative
of the timing of plunger actuations for the plunger 33 to sequentially contact the
blister pockets in the row, as the blister pack is moved in a longitudinal direction
under the head 25.
[0055] The signals from the second camera 19 are thus received and processed by the controller
51 which generates an output to control head motor 27 to adjust the transverse position
of the head 25 such that the plunger 33 is transversely aligned with a first row of
blister pockets. The first conveyor belt 17 continues to move the blister pack longitudinally
towards the head 25 until the first pocket of the first row of pockets on the blister
pack is beneath the plunger 33, that is, the pocket is longitudinally and transversely
aligned with the tip of the plunger 33. The plunger actuator 31 is then activated
by the controller such that the plunger tip is rapidly moved downwardly into contact
with the blister pocket, forcing the pill inside the pocket to pierce the foil, drop
through the aperture 37 in the dispensing plate 35, into the pill tray 39 and into
the pill receptacle 41.
[0056] The first and second conveyors 17, 47 then move the blister pack longitudinally such
that the next blister pocket in the first row of pockets is aligned with the tip of
the plunger 33, wherein the dispensing process is repeated.
[0057] Thus, the dispenser 1 can automatically measure and dispense the required number
of pills from an entire row of a blister pack relatively quickly, and without intervention
from an operator.
[0058] The signals generated by the second camera 19 may also indicative of the number of
rows of pill pockets on the blister pack. Thus the transverse position of the dispensing
head 25 is altered via a control signal generated by the controller 51 such that the
tip of the plunger 33 is subsequently transversely aligned with the second row of
pill pockets. The transverse position of the blister pack on the first conveyor 17
remains constant in this example.
[0059] When the transverse position of the dispensing head 25 has been altered so as to
be aligned with the second row of blister pockets, the longitudinal motion of the
first and second conveyor belts 17, 47 is reversed such that the blister pack moves
back towards the loader 11, at least to a position where the first blister pocket
is aligned with the tip of the plunger 33 such that the pill dispensing process described
above in connection with the first row of blister pockets can then take place with
the second row of blister pockets. Thus once the blister pack has been moved back
to the start position, the direction of motion of the conveyors 17, 47 resumes their
initial longitudinal direction to move the blister pack underneath the plunger 33
and onto the waste receptacle 49, the dispensed pills falling into the pill tray 39
and into the pill receptacle 41.
[0060] It will be appreciated that variations of the above process are envisaged in order
to operate the dispenser 1 as efficiently as possible. For example, the loader 11
may be operative to sequentially load multiple blister packs onto the first conveyor
17 such that more than one blister pack is on the conveyor 17 at any one time. Likewise
it may be possible to dispense pills from the blister pockets of a second row of pockets
whilst the conveyor 17 is moving in the reverse direction - ie the pills in the first
row can be dispensed with the blister pack moving past the plunger 33 in a first direction,
whilst the pills in the second row can be dispensed with the blister pack moving in
the opposite direction. It is also envisaged that the dispensing head may operate
transversely across each line of blister packs so as to dispense pills from the first
transverse line of pockets, move the blister pack longitudinally such that the second
line of pockets is longitudinally aligned with the plunger, and then dispense pills
transversely from the second line of pockets.
[0061] The pill receptacle 41 may be provided with electronic identification such as a barcode,
RFID or any other form of electronic identifier used to indicated the type and quantity
of pills in the receptacle 41. The dispenser 1 may be automated such that once a stack
of blister packs has been loaded into the loader 11, the electronic identifier on
the receptacle is scanned by a suitable scanner on the dispenser 1, the scanning signal
being used by the controller 51 to dispense the required number of pills into the
receptacle 41. Likewise, the operator may manually select the number of pills to be
dispensed via the touchscreen or the like.
[0062] It is envisaged that the operating speed of the conveyors 17, 47 and the plunger
33 may be varied according to a desired throughput, or according to the physical characteristics
of the pills to be dispensed. Likewise the force applied by the actuator 31 to the
plunger 33 may be controlled accordingly and indeed a force feedback system may be
provided to automatically control the force applied to the blister pockets in relation
to the feedback signal received.
[0063] With reference to Figure 4, the aperture 37 in the pill dispensing plate 35 may be
of any desired shape or size to enable the pill to be dispensed through the aperture
and the foil to remain attached to the blister pack. For example, the aperture 37
may be egg shaped or triangular. The aperture 37 may comprise a cut-out at one margin
of the plate 35 to encourage the pill to incline through the cut-out when pressure
is applied by the plunger 33.
[0064] The conveyors 17, 47 may be comprise any suitable belt or track and may be provided
with ribs or protrusions to help grip the blister pack and resist it slipping along
the conveyors 17, 47.
[0065] The control means 51 may include a readable memory operative to store details of
the pills dispensed in a given time. Such details may include the type of pill, the
number of pills, and the intended recipient of the pills for example. A printer may
be provided to print suitable reports in this regard.
[0066] In a modified dispenser, a modified pill dispensing plate is movably mounted on the
dispenser 1 and is transversely movable by a separate plate motor controlled by controller
51 relative to the pill dispensing head 25. The motor may comprise a linear motor
or a stepper motor driving an indexing screw mechanism for example. The modified plate
may additionally or alternatively be longitudinally movable relative to the pill dispensing
head 25.
[0067] The modified plate comprises a plurality of pill dispensing apertures and examples
of these can be seen with reference to Figure 4. Other shapes, sizes and profiles
of aperture are envisaged as may be required to dispense pills of the desired shape
and size.
[0068] In use, a plate control signal is generated by the controller 51 in response to the
blister pack signal from the second camera 19. The blister pack signal is indicative
of the shape and size of the detected blister pockets and is used by the controller
51 to match the detected blister pocket with the appropriately shaped, sized and profiled
aperture on the modified plate. In particular the controller 51 generates a plate
control signal that activates the plate motor to move the plate such that the required
aperture is longitudinally and transversely aligned with the plunger 33. Thus the
plate is independently movable relative to the dispensing head 25.
1. An automated blister pack pill dispenser comprising a blister pack loader operative
to receive a blister pack and load the blister pack onto a platform, and at least
one blister pack sensor operative to sense the blister pack on the platform and to
generate at least one blister pack signal indicative of the transverse and longitudinal
positions of the pills on the blister pack relative to a datum, the dispenser further
comprising a pill dispensing head comprising a plunger driven by an electrically powered
plunger actuator, and a pill dispensing plate comprising an aperture located beneath
the plunger, the plate being configured to at least partially support the blister
pack, at least one motor being provided to enable relative movement between the pill
dispensing head and the platform in directions transverse and longitudinal to the
datum, an electronic controller being provided operative to receive the blister pack
signal and to process the blister pack signal to control the motor such that the relative
transverse position and the relative longitudinal position between the pill dispensing
head and the datum are arranged such that a pill pocket of the blister pack is transversely
and longitudinally aligned with the plunger, the controller being further operative
to subsequently activate the plunger activator to drive the plunger to push a pill
from the aligned blister pack pocket, the dispensed pill dropping through the aperture
in the pill dispensing plate.
2. The dispenser of claim 1 wherein the pill dispensing head is mounted on one end of
a cantilevered transversely extending arm, the other end of the transverse arm being
mounted on the dispenser.
3. The dispenser of claim 1 or claim 2 wherein the pill dispensing head is mounted on
a carriage movably mounted on a track on the dispenser.
4. The dispenser of any one of the preceding claims wherein the loader comprises a chute
having at least one movable side to enable the width of the loader to be adjustable.
5. The dispenser of claim 4 wherein the chute is inclined relative to the platform.
6. The dispenser of any one of the preceding claims wherein the platform is provided
with at least one side guide against which a margin of the blister pack abuts in use.
7. The dispenser of claim 6 wherein the side guide is movably mounted on the dispenser
such that the transverse position of the side guide can be altered so as to enable
the width of the platform to be adjustable.
8. The dispenser of any one of the preceding claims wherein the blister pack sensor further
comprises a width detector operative to generate a width signal indicative of the
width, that is, the transverse dimension, of a blister pack.
9. The dispenser of claim 8 wherein the controller is operative to receive and process
the width signal, to automatically adjust the transverse position of the movable loader,
the side of the movable side guide of the platform and the pill dispensing head to
correspond to the width of the blister pack.
10. The dispenser of any one of the preceding claims wherein the blister pack sensor comprises
a blister pack sensor camera.
11. The dispenser of claim 8 or claim 9 wherein the width detector comprises a width detector
camera.
12. The dispenser of claim 10 or claim 11 wherein the camera includes an illuminator to
illuminate an area detected by the camera.
13. The dispenser of any one of the preceding claims wherein the loader is provided with
a blister pack indexing mechanism operative to index one blister pack at a time from
the loader onto the platform.
14. The dispenser of claim 13 wherein the indexing mechanism comprises upper and lower
retractable pins, the pins being movable from a projecting position in which they
project into the chute to support a blister pack in the chute, to a retracted position
in which the blister pack can drop down the chute, the upper and lower pins being
controlled by the controller to sequentially project and retract such that one blister
pack at a time drops down the chute.
15. The dispenser of any one of the preceding claims wherein the platform comprises a
conveyor operative to convey the blister pack from the loader to the pill dispensing
head.
16. The dispenser of claim 15 wherein the conveyor comprises a conveyor belt.
17. The dispenser of claim 15 or claim 16 wherein the controller is operative to control
the conveyor, when a blister pack is on the conveyor, to index adjacent blister pockets
of the blister pack to a position longitudinally aligned with the plunger.
18. The dispenser of any one of claims 15 to 17 wherein the conveyor comprises an inlet
and an outlet conveyor, longitudinally opposed on each side of the plate.
19. The dispenser of any one of the preceding claims wherein a pill retaining tray is
provided beneath the pill dispensing plate to retain pills that drop through the aperture.
20. The dispenser of claim 19 wherein a dispensed pill receptacle is provided to receive
dispensed pills from the pill retaining tray.
21. The dispenser of claim 20 wherein the dispensed pill container comprises an electronic
identifier such as a bar code or RFID chip for example.
22. The dispenser of any one of the preceding claims wherein the pill dispensing plate
is movable with the pill dispensing head.
23. The dispenser of any one of the preceding claims wherein the dispenser is provided
with a plurality of plates each provided with differently shaped and/or differently
sized apertures.
24. The dispenser of any one of the preceding claims wherein the plate comprises a plurality
of differently shaped and/or differently sized apertures, the plate being movably
mounted on the dispenser such that a selected aperture can be aligned with the plunger,
a plate motor being provided to move the plate in response to a plate control signal
from the controller, the plate control signal being generated in dependence upon the
size and shape of blister pocket detected by the blister pack sensor such that the
selected aperture corresponds to the detected blister pocket.
25. The dispenser of any one of the preceding claims wherein the aperture comprises a
cut-out portion cut away from a side margin of the plate.
26. The dispenser of any one of the preceding claims wherein the controller includes a
touch screen.
27. The dispenser of any one of the preceding claims wherein the controller is operative
to store data relating to the pill or pills dispensed.
28. A dispenser assembly comprising a dispenser according to any one of claims 1 to 27
mounted on a dispenser desk.
29. The dispenser assembly of claim 28 wherein the dispenser desk comprises a trolley
provided with wheels to enable the desk and dispenser to be moved.