WO1996004171A1 - Appareil et procede de comptage et d'emballage automatiques d'objets separes - Google Patents

Appareil et procede de comptage et d'emballage automatiques d'objets separes Download PDF

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Publication number
WO1996004171A1
WO1996004171A1 PCT/US1995/009894 US9509894W WO9604171A1 WO 1996004171 A1 WO1996004171 A1 WO 1996004171A1 US 9509894 W US9509894 W US 9509894W WO 9604171 A1 WO9604171 A1 WO 9604171A1
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WO
WIPO (PCT)
Prior art keywords
objects
tray
container
image data
reject
Prior art date
Application number
PCT/US1995/009894
Other languages
English (en)
Inventor
Thomas Carl Stange
James Michael Dinanno
John Paul Maillet, Jr.
Richard Neil Heino
Original Assignee
Stokes-Merrill Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US08/285,806 external-priority patent/US5463839A/en
Application filed by Stokes-Merrill Corporation filed Critical Stokes-Merrill Corporation
Priority to AU33604/95A priority Critical patent/AU3360495A/en
Publication of WO1996004171A1 publication Critical patent/WO1996004171A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00—Automatic control, checking, warning, or safety devices
    • B65B57/20—Applications of counting devices for controlling the feed of articles

Definitions

  • the present invention relates to an apparatus and methods for counting and packaging small, discrete objects, such as tablets and capsules, and more particularly, to an apparatus and methods for automated, high-speed counting into predetermined quantities and 10 packaging of such objects.
  • Automatic high-speed counting and packaging ,c apparatus are used routinely by pharmaceutical manufacturers to package predetermined quantities of pills, tablets, capsules and similar discrete dosage forms. To meet the requirements of the pharmaceutical industry, such apparatus must be capable of rapidly ⁇ ⁇ filling a large number of containers, typically on the order of one hundred to several hundred containers per minute, with a predetermined quantity of product in each container. Such apparatus should also be able to accurately distinguish chipped, broken or otherwise ?c defective product from intact product and to segregate containers containing unacceptable product. Since automatic counting and filling apparatus are typically used to package several different types of product, they should also be designed to facilitate ease of disassembly
  • Slat counters perhaps the fastest devices of this type, include slats fitted onto a moving chain which rotates the slats through a hopper containing tablets or capsules.
  • the slats have a predetermined number of cavities corresponding to the predetermined quantity of product to be packaged, and each cavity is filled with, for example, a tablet as the slat rotates through the hopper.
  • the predetermined number of tablets are directed into a container.
  • Disk counters are another type of commercially available automatic counting and filling apparatus. These devices include a rotating disk which has a series of holes to hold tablets, capsules or similar products. The holes are filled with product in one area of the device, and as the disk rotates the product falls out of the holes and are diverted into a container. As in the case of the above-described slat counter, the disk counter is difficult to clean, and a change in either product size or quantity requires that the disk be changed, which in turn results in significant down time. Counters are also known which continuously drop product from a hopper onto a vibrating feed tray which advances the product downstream to a photosensor for counting. When a quantity of product equaling the predetermined quantity is counted by the photosensor, the product is directed into a container.
  • the photosensor typically employed is an opposed beam photoelectric sensor comprising a light source and an opposed receiver. When an object passes in front of the sensor, the beam is interrupted, thus signaling to the controller to count the respective object. Because these sensors typically lack the requisite sensitivity, they are not susceptible to differentiating between objects of different size, and therefore typically cannot differentiate between damaged or defective and intact product. If, on the other hand, the sensitivity of such devices is increased too much, they often cannot differentiate between the objects to be counted and other loose debris or particles, such as dust. Moreover, these sensors have proven to be particularly susceptible to dust, which at times can render the sensor incapable of accurately counting objects. Thus, the filled container too frequently contains damaged product and a quantity of product which does not correspond to the desired amount.
  • One object of the present invention to overcome the drawbacks and disadvantages of prior apparatus and methods for counting and packaging discrete objects.
  • One object of the present invention to provide a counting device that rapidly separates and accurately counts predetermined quantities of discrete objects, such as tablets and capsules.
  • the present invention provides a device for counting a predetermined quantity of discrete objects. While the apparatus will be described in connection with counting dosage forms such a tablets and capsules, the apparatus may be used to count any small discrete objects, such as nuts, bolts screws, buttons, etc.
  • the device includes a feed tray which defines an axis extending between an inlet portion and a discharge portion of the tray. Objects deposited on the inlet portion of the tray are advanced along the axis and are singularized or separated from one another for counting by the time they arrive at the discharge portion of the tray.
  • the tray has at least one guide path including a plurality of segments for transporting objects from the inlet to the discharge portion of the tray. Each of the objects defines a direction of movement along the axis, and at least some of the segments are oriented at an angle with respect to the axis, the angle at which respective segments are oriented becoming decreasingly oblique toward the discharge portion of the tray.
  • the device further includes means for advancing objects along the guide path from the inlet portion toward the discharge portion of the tray. Since the guide path includes at least some segments which define a direction of movement oriented at an angle with respect to the axis, and since the angle becomes decreasingly oblique toward the discharge portion of the feed tray, objects advance along the guide path at differing velocities depending on their particular location on the path. For example, objects located on a segment of the path near the inlet portion of the tray and having a direction of movement oriented at highly oblique angle to the axis move at a much slower velocity than objects located on a segment of the path near the discharge portion of the tray and having a direction of movement oriented parallel or nearly parallel to the axis.
  • the tray is able to rapidly singularizing the objects as they advance from the inlet portion to the discharge portion of the feed tray. Accordingly, the present invention employs a feed tray which is much shorter than those typically found in prior art automatic counting devices, wherein the guide paths extend parallel to the axis throughout their entire length. Moreover, the apparatus taught by the invention is capable of effecting a complete separation of the objects from one another while operating at much higher object feed velocities as compared with prior art devices.
  • the device also includes means for counting the quantity of singularized objects received at the discharge portion of the tray and means for interrupting the advancement of objects along the guide path when the quantity of objects counted equals the predetermined quantity.
  • Control means connected to the means for counting and the means for interrupting is also provided. The control means receives data from the counting means which correspond to the quantity of objects counted, and the control means activates the means for interrupting to temporarily stop the advancement of objects along the guide path when the data received correspond to the predetermined quantity.
  • the feed tray has a plurality of guide paths each of which includes a plurality of reversely arcuate segments which increase in radius toward the discharge portion of the tray.
  • the guide paths define an undulating or wave like pattern, wherein the waves become flatter, i.e., decreasingly less arcuate, toward the discharge portion of the feed tray.
  • the counting means in a preferred embodiment of the invention comprises a camera for imaging objects advancing along the guide paths, an optical sensor for registering the image of each object as a pixel array, and a processor for converting the registered image into data to be forwarded to the control means.
  • the data for groups of at least two guide paths are combined, and when the data correspond to the predetermined quantity, the control means activates the means for interrupting to temporarily stop the advancement of objects along that group of guide paths.
  • the means for interrupting utilized in a preferred embodiment includes a manifold supporting a plurality of pneumatically operated gates.
  • the gates comprise a piston and cylinder assembly actuated between an open position and a closed position by an associated solenoid connected to the control means for alternately permitting and interrupting advancement of objects along the guide path.
  • the present invention provides an apparatus for counting and packaging a predetermined quantity of objects.
  • the apparatus includes the counting device described above together with means for transferring objects from the discharge portion of the tray to a container to fill the container with the predetermined quantity of objects.
  • the apparatus further includes means for delivering at least one empty container to a fill position for receiving the predetermined quantity of objects from the transfer means, means for discharging the filled container from the fill position, and means for segregating filled bottles containing intact product from those containing damaged or defective objects.
  • a conveyor for delivering empty bottles to and removing filled bottles from the counting device.
  • the means for transferring the predetermined quantity of objects to the bottles delivered by the conveyor includes a plurality of funnels and associated chutes; each of the funnels receives the predetermined number of objects at its upper end from one or more guide paths and discharges objects from its lower end into an associated chute and then directly into a bottle.
  • Indexing means associated with the conveyor are provided for moving empty bottles from an infeed lane of the conveyor to a fill position located beneath the lower end of the chutes, and for moving filled bottles from the fill position to a discharge lane of the conveyor.
  • the conveyor is provided with a diverter actuated by the controller to segregate bottles containing damaged product from the discharge lane of the conveyor.
  • the present invention provides an optical sensor that repetitively scans singularized objects and generates image data indicative of at least one dimension of each scanned object.
  • the image data is indicative of object length and object area.
  • the optical sensor includes a pixel array.
  • a control computer is coupled to the optical sensor, and determines object length based on the number of consecutive scans generating image data corresponding to the respective object, and determines object area based on the number of consecutive pixels generating image data of the object for all scans.
  • the control computer assigns the object image data to respective lanes and containers, and counts the total number of objects discharged into each container. Upon approaching the desired count for each container, the control computer successively closes each lane discharging into the container to obtain the desired count.
  • the control computer also compares the object image data to corresponding set points, and generates classification flags indicative of whether each object is a reject or not.
  • the apparatus comprises a database of quality profiles corresponding to respective object types. Pursuant to each quality profile, the control computer can automatically compensate for each reject object by adding another object to the container. If the number of objects exceeds an overcount limit set by the quality profile, the container is rejected. Pursuant to a learn mode, the control computer is responsive to image data to select vibrational amplitude settings for the feed tray corresponding to respective object types to reduce object bounce and enhance scan repeatability.
  • the control unit records a first set of object image data for a first group of objects at a first vibrational amplitude, records a second set of object image data for a second group of objects at a second vibrational amplitude, compares the first and second sets of image data, repeats these steps until the comparison results meet corresponding set point criteria and selects the vibrational amplitude corresponding to the set points.
  • the control unit also automatically determines the spacing between singularized objects based on the image data, and adjusts the vibrational amplitude of a prefeed tray to substantially achieve an object spacing set point.
  • a database of operating parameters for the optical sensor are also provided, wherein each set of parameters corresponds to a respective object type.
  • the control unit is responsive to the image data to select a set of operating parameters corresponding to the type of object being scanned.
  • One advantage of the present invention is that not only is each object accurately counted, but image data is generated indicative of at least one dimension of each scanned object. Accordingly, the dimensional characteristics of each object, such as area and length, can be accurately determined and compared to control limit values to ensure quality control standards.
  • the image data can be employed to automatically control the vibrational amplitude of each feed tray to reduce object bounce to enhance scan repeatability, while maintaining a relatively fast object speed and close object spacing to maximize the rate at which the objects are filled into containers.
  • FIG. 1 is a perspective view of an apparatus embodying the present invention for automatically counting and packaging discrete objects.
  • FIG. 2 is a side, elevational view of the apparatus of FIG. 1 with certain parts removed for clarity.
  • FIG. 3 is a top, plan view in partial cross-section of the gating manifold of the apparatus of FIG. 1 with certain parts removed for clarity, which is used for controlling the discharge of singularized objects into containers.
  • FIG. 4 is a top, plan view of the conveyor and bottle-actuator assembly of the apparatus of FIG. 1 for transporting containers to be filled.
  • FIG. 5 is a block diagram of the electronic control components of the apparatus of FIG. 1 for automatically counting and packaging objects into containers.
  • FIG. 6 is a block diagram illustrating the software code modules for automatic control and operation of the apparatus of FIG. 1.
  • FIG. 7 is a flow chart illustrating conceptually the procedural steps of the learn mode of the apparatus for optimizing object feed rates and establishing set points for particular product types.
  • FIG. 8 illustrates a screen display of the operator interface computer of the apparatus showing a summary of the learn mode for an exemplary object type.
  • FIG. 9 illustrates a screen display of the operator interface computer showing statistical process control data and process parameters for an exemplary object type generated during the learn mode of the apparatus.
  • FIG. 10 illustrates a screen of the operator interface computer displaying product parameters for an exemplary object type.
  • FIG. 11 illustrates a screen displaying the quality profile for an exemplary object type.
  • FIG. 12 illustrates a run mode screen displaying realtime, status information in graphical and alphanumeric formats.
  • FIG. 13 illustrates a screen defining the parameters of an exemplary container type.
  • FIG. 14 is a partial front perspective of the apparatus shown in FIG. 1.
  • FIG. 15 is a top plan view of the feed tray which forms a part of the apparatus shown in FIG. 1.
  • FIG. 16 is a partial side elevation showing the latching mechanism for the gating manifold of FIG. 3.
  • FIG. 17 is a side elevation of the vibrator and associated latch for the feed tray of the apparatus shown in FIG. 1.
  • FIG. 18 is a partial section of the bottle actuator illustrated in FIG. 4.
  • an apparatus embodying the present invention for automatically counting and packaging discrete objects is indicated generally by the reference numeral 10.
  • the apparatus 10 comprises a transportable housing and frame assembly 12 carrying a hopper 14 for holding the discrete objects to be counted and packaged (not shown) , a prefeed tray 16 mounted below the hopper, and a main feed tray 18 mounted downstream of the prefeed tray to receive and singularize the objects discharged from the hopper and prefeed tray.
  • a transportable housing and frame assembly 12 carrying a hopper 14 for holding the discrete objects to be counted and packaged (not shown) , a prefeed tray 16 mounted below the hopper, and a main feed tray 18 mounted downstream of the prefeed tray to receive and singularize the objects discharged from the hopper and prefeed tray.
  • a transition guide 20 is mounted downstream of the main feed tray 18, and a collection block 22 is mounted downstream of the transition guide to receive the singularized objects from the main feed tray and guide them into respective containers, as is described further below.
  • a vibrator 24 is coupled to the prefeed tray 16 to vibrate the tray and in turn drive the objects from one end of the tray to the other.
  • a first vibrator 26 is coupled to the inlet end of the main feed tray 18, and a second vibrator 28 is coupled near the outlet end to vibrate the tray, and in turn transport and singularize the objects as they move from one end of the tray to the other.
  • the main feed tray also slopes downwardly with respect to the horizontal from its inlet toward its outlet end to facilitate the movement and separation of objects.
  • the main feed tray is sloped at an angle of from about 3° to about 8° and preferably at an angle of about 7°, although the invention is in no way limited in this regard.
  • the tray 18 may be sloped more or less than the above-described typical range.
  • the prefeed tray 16, main feed tray 18, and transition guide 20 each define a plurality of lanes or guide paths 30 extending from the inlet to the outlet end of the respective part.
  • the corresponding guide paths of the two feed trays and transition guide are aligned with each other so that as each object is discharged from one part to the next, it is maintained within the respective guide path.
  • the apparatus could employ a greater or lesser number of guide paths, and this is easily accomplished simply by replacing parts 16, 18, 20 and 22 with parts defining the desired number of paths.
  • each guide path 30 within the main feed tray 18 defines an undulating or wave-like pattern wherein each wave is decreasingly less arcuate toward the discharge or outlet end of the tray.
  • a plurality of segments of any guide path each define a respective direction of movement, and the angle defined by each direction of movement with respect to the central axis of the tray (or with respect to the drive vector of the tray as defined by the direction of movement of the vibrators 26 and 28) becomes decreasingly oblique toward the outlet end of the tray.
  • This configuration effectively causes objects to advance along each guide path at differing velocities depending upon their locations on the path, thus facilitating a rapid separation and singularizing of the objects as they advance from the inlet to the outlet end of the tray.
  • This configuration also permits the feed tray to be vibrated at higher frequencies and greater amplitudes than prior art devices.
  • the feed tray 18 is typically vibrated at from about 80 Hz to about 100 Hz and preferably about 82 Hz, whereas prior art devices operate at about 60 Hz.
  • the relatively fast vibrational frequency, high vibrational amplitude and unique configuration of the feed tray of the present invention permit singularizing of the objects at much faster rates than are possible with prior art devices.
  • prior art devices typically utilize up to three feed trays to singularize objects for counting
  • the present invention employs a single tray having a length of from only about 20 inches to about 30 inches and preferably about 26 inches.
  • Higher object feed velocities are also possible with a device embodying the present invention as compared with prior art counting and filling apparatus. Whereas prior art devices operate at a feed velocity of no more than about 25 ft./min., the present invention achieves feed velocities of up to 60 ft./min.
  • the collection block As shown in FIGS. 1 and 14, the collection block
  • the collection block 22 also defines a plurality of lanes or guide paths 30, each being aligned with a corresponding guide path of the transition guide 20 to receive the respective objects discharged through the path.
  • the collection block 22 also defines a lane-merging area located downstream of the lanes or guide paths 30 formed by three funnel-shaped lanes 32, each funnel being aligned with a group of guide paths to receive the singularized objects from the respective group.
  • Each funnel 32 in turn directs the singularized objects through a chute 33 and into a respective container, as is described further below.
  • the chutes 33 are formed together as a single change part 35, and the operator of the apparatus 10 simply selects the part having chutes properly contoured for the size and shape of the particular containers being filled.
  • a vacuum slot 34 is defined between the outlet end of the main feed tray 18 and the inlet end of the transition guide 20, and a sensor slot 36 is defined between the outlet end of the transition guide and the inlet end of the collection block 22.
  • a vacuum manifold 39 is located within the housing and frame assembly 12 immediately beneath the vacuum slot 34 to create a suction, and in turn draw dust or loose particles passing over the slot into the manifold and away from the containers being filled.
  • An optical sensor 38 is mounted within the housing and frame assembly 12 and aligned with the sensor slot 36, as illustrated in dashed lines in FIG. 2, to scan the singularized objects as they pass over the slot from the transition guide to the collection block.
  • the optical sensor 38 is a linear array picture processing camera, such as the "LAPP 1100" camera from Integrated Vision Products AB of
  • This particular camera has a linear array (i.e., a single row) of 128 pixels, each pixel having dimensions of 35 x 35 ⁇ m, and has image sensing, digitization and picture-processing capabilities.
  • a background light 40 is mounted on the opposite side of the sensor slot 36 relative to the camera 38 and is tuned to the optimum bandwidth of the camera in order to minimize the effect of variations in ambient light intensity, object reflectivity or other potential interferences.
  • the light 40 is a phosphor lamp tuned to a frequency of about 680 nm.
  • a gating manifold 42 is mounted on the housing and frame assembly 12 adjacent to the collection block 22 and is provided with air intake and return lines 45.
  • the manifold comprises a plurality of gates 44 for controlling the discharge of singularized objects into containers.
  • each gate 44 is mounted on a respective sleeve or piston 46 coupled to a solenoid valve and cylinder assembly 48 and is aligned with a respective guide path 30 on the collection block 22.
  • Each solenoid valve and cylinder assembly 48 is actuated to drive the respective sleeve and gate between an extended position to block the passage of objects through the respective guide path 30, and a retracted position to permit the passage of objects through the respective guide path, as is described further below.
  • Each gate 44 is preferably made of a plastic material, and defines a mounting aperture 51 forming a snap fit with the free end of the respective sleeve to permit detachment and reassembly of the gates without tools for cleaning and/or reconfiguring the apparatus to process different products.
  • the gating manifold 42 also includes a pair of sockets 50 mounted on opposite ends of the manifold for detachably mounting and electrically connecting the manifold to corresponding mounting pads 52 carried on the housing and frame assembly 12.
  • Each socket 50 includes a multi-pin electrical connector 54 connected to a plurality of the gate solenoids 48, and each mounting pad 52 includes a corresponding connector 56 for electrically connecting the gating manifold to the electronic control components of the apparatus upon mounting the manifold to the frame and housing assembly, as is described further below.
  • a pair of latches 58 are each pivotally mounted to a pivot pin 61 carried by a respective mounting pad 52, and each latch defines a recess to receive a corresponding pin 60 carried by the respective socket 50 to lock the socket and manifold to the mounting pad.
  • a pair of support brackets 62 are each mounted to the frame and housing assembly 12 below a respective mounting pad 52 to provide additional support for the gating manifold when detachably mounted to the pads. The gating manifold 42 can thus be quickly mounted to and detached from the housing and frame assembly without tools to facilitate changeover for processing different products and/or cleaning of the apparatus.
  • the vibrator 26 includes a pair of tray latches 166 (one shown) which mate with corresponding slots 167 formed in the underside of the main feed tray 18.
  • the tray latches are spring biased in the latch position (shown in solid line) , wherein the latches engage the slots in the tray, and an associated pneumatic actuator 168 is provided to move each latch to the unlatched position (shown in dashed line) for removal of the tray.
  • a conveyor and bottle-actuator assembly 64 is mounted in front of the transportable housing and frame assembly 12 beneath the collection block 22 to fill containers with singularized objects as they are discharged through the funnels 32 and chute 33.
  • the assembly 64 comprises a closed-loop conveyor 66 for transporting containers, in this case substantially cylindrical-shaped bottles 68, to and from a fill station 70 located beneath the funnels 32 and chute 33.
  • the housing and frame assembly 12 is provided with an hydraulic system to raise and lower the assembly and adjust its height relative to the conveyor, if necessary.
  • the conveyor defines an entry guide path 72, which is slightly wider than each bottle 68, thus causing the bottles to form a single file as they are transported toward the inlet side of the filling station, as indicated by the arrow in FIG. 4. on the outlet side of the filling station, the conveyor defines an outlet guide path 74 and a parallel reject path 76.
  • a diverter gate 78 is pivotally mounted between the outlet and reject paths, and is coupled to an actuator (not shown) to move the diverter between a default position to normally guide the filled containers into the outlet path 74, as shown in solid lines in FIG. 4, and a reject position to divert any reject bottles into the reject path 76, as shown in dashed lines in FIG. 4.
  • An outlet sensor 80 is mounted adjacent to the outlet path 74, and is preferably an opto-electric sensor to sense the passage of each container passing through the outlet path.
  • a reject sensor 82 is mounted adjacent to the reject path 76, which is preferably also an opto-electric sensor to sense the passage of each rejected container into the reject path.
  • a series of bottle actuators 84 are mounted adjacent to the filling station 70 on one side of the conveyor.
  • Each bottle actuator 84 comprises a bottle pusher 86 detachably mounted to a drive arm or piston 88, which is in turn mounted within a respective cylinder and pneumatic valve assembly 90.
  • each pusher 86 defines a curved surface 92 on one end shaped to substantially conform to the curvature of the respective bottle or container being processed, and as shown in FIG. 18, defines on its opposite end a slot 94 communicating with a hollow cavity 96 open on the underside of the pusher for receiving and encapsulating the free end of the respective piston 88. Accordingly, each pusher 86 is detachably mounted to the respective piston 88 to permit the pushers to be removed and replaced without tools to process different types of containers by simply lifting each pusher upwardly and away from the respective piston.
  • Each cylinder and valve assembly 90 defines a notch 98 on its underside to receive and encapsulate a rail 100 mounted on the conveyor assembly to align the respective bottle actuator with the fill station.
  • Each bottle actuator 84 also comprises a latch 102 pivotally mounted to the backside of the respective cylinder and valve assembly 90 to secure the actuator to the conveyor without tools once the actuator is slid into place.
  • the bottle actuators 84 and/or the pushers 86 can be quickly and easily removed and replaced without tools to accommodate different types of containers and/or different numbers of actuators, thus facilitating a rapid changeover for processing different products.
  • the apparatus 10 further comprises an operator interface computer (OIC) 104 carried by a swing-arm 106 on the housing and frame assembly 12, and a control system computer (CSC) 108 coupled to the OIC and mounted within the housing and frame assembly.
  • the OIC 104 is preferably a touch-screen type personal computer comprising a central processing unit (CPU) 110 and a communication card 112 coupled through a serial port to a corresponding communication card 114 on the CSC.
  • the OIC 104 enables operator interaction with the CSC 108 to control the automatic operation of the apparatus, including setting operating characteristics for the CSC, providing status information, and enabling troubleshooting, testing and communication with external computers to inquire, for example, about production data.
  • the CSC 108 further comprises an optical data card 116 coupled to the optical sensor 38 for receiving the object image data, and a data acquisition processor (DAP) 118 for performing digital and analog input and control.
  • the DAP 118 is coupled to a pair of analog signal conditioners 120 for receiving sensor signal data and in turn controlling machine components throughout the apparatus.
  • the first analog signal conditioner 120 is coupled to a light level sensor 122 for sensing the light intensity of the background light 40, and to the vibrator controls for controlling the vibrator 24 coupled to the prefeed tray, and the first and second vibrators 26 and 28 coupled to the main feed tray.
  • An optical sensor 124 is mounted on the hopper 14, as shown in FIG. 1, and is likewise coupled to the first signal conditioner 120 for transmitting signals indicative of the product level in the hopper.
  • Another sensor 126 is coupled to hydraulic actuators located on the base of the apparatus (not shown) for adjusting the level of the apparatus, and transmits signals to the first signal conditioner indicative of the machine height or level.
  • the second signal conditioner 120 is coupled to a hopper baffle 128 for adjusting the rate at which objects are discharged from the hopper 14.
  • the second signal conditioner 120 is also coupled to a conveyor motor 130 for controlling the speed of the conveyor 66, and to a pneumatic regulator 132 for controlling the air pressure to pneumatic components throughout the apparatus.
  • the DAP 118 is also coupled through a multiplex distribution board 134 to a plurality of digital input ports 136 and digital output ports 138 for obtaining status information and controlling all digital components of the apparatus. Accordingly, output ports 138 are coupled through the electrical connectors 54 and 56 to each of the solenoids 48 of the gating manifold 42 to control the discharge of singularized objects into containers, as is described further below. Output ports 138 are also coupled to the cylinder and pneumatic valve assemblies 90 of the bottle actuators 84 to control the indexing of bottles through the filling station 70, and to the actuator (not shown) of the diverter gate 78 to control reject processing.
  • the input ports 136 are coupled to the outlet sensor 80 and reject sensor 82 of the conveyor and bottle-actuator assembly 64 to receive the signals transmitted therefrom.
  • the CSC 108 also includes a CPU 140 functioning as a data manager for organizing and controlling the operating sequence of the software code modules resident in the CSC, OIC 104 and optical sensor 38.
  • the software code modules include a traffic control and serial communications module 142, a status and comparison module 144, a classifying objects module 146, and a counting and reject evaluation module 148 resident in the CPU 140 of the CSC, along with a DAP module 150 performing input/output, evaluation and timing functions, and an optical sensor module 152 resident in the optical sensor 38 for image data preprocessing and light tests.
  • the DAP 118 monitors the light level as measured by the light sensor 122 and transmits the light level data to the CPU 140. If the light intensity is outside of a predetermined range, a fault signal is generated to terminate operation and correct the situation so that scanning can be effectively performed.
  • the linear pixel array of the sensor which is illustrated schematically as 154 in FIG. 5, repetitively scans the sensor slot 36 at a predetermined, substantially constant rate, i.e., "X" scans per second, thus scanning each singularized object as it passes over the slot between the transition guide 20 and collection block 22.
  • the sensor 38 comprises a buffer 156 including a plurality of shift registers coupled to the linear pixel array 154 for receiving the image data from each scan. Accordingly, after each scan, a respective line of image data is transmitted to the first register of the buffer, indicating (1) the number of singularized objects scanned and the guide path associated with each such object, and (2) the width of each respective object portion scanned.
  • the number of objects counted within each line scan is based on the groups of consecutive pixels generating image data within the line scan. For example, if there are 12 guide paths and 128 pixels in the linear array, then approximately every 10 consecutive pixels are associated with a respective guide path. Thus, each group of consecutive pixels generating image data corresponds to an object within a respective guide path, and the number of consecutive pixels is indicative of the width of the respective object portion scanned.
  • the length of each scanned object is based on the number of consecutive scans for which the respective group of pixels generate image data.
  • each line of image data is generated, it is read into the first register of the buffer 156, and each of the remaining registers are successively shifted to accommodate each new line of data.
  • the buffer is filled with image data, logical comparisons are performed to connect each image to a respective feed path. Then, once the buffer is filled with data, the buffer is emptied and the image data is transmitted via the optical data card 116 to a buffer within the CPU 140.
  • this module matches each object to its respective guide path, and assesses the length and area of the object. As described above, the length determination is made based on the number of scans of image data corresponding to the respective object. The area determination is made based on the number of consecutive pixels transmitting the image data for all scans corresponding to the respective object.
  • This module compares the length data, e.g., "x" number of scans, and the area data, e.g., "y” number of pixels, to predetermined set points for the particular type of product being processed, and transmits a respective classification flag indicative of the results to the counting and reject evaluation module 148. If the length and area determinations are within predetermined acceptable ranges, then a "good” flag is transmitted. If, on the other hand, the product is over sized in either respect, an "over size” flag is transmitted, and if under sized in either respect, an "under size” flag is transmitted.
  • the counting and reject evaluation module 148 assigns a counter to each guide path, and based on the respective guide paths discharging into each funnel 32, this module continuously counts the total number of objects discharged through each funnel and chute into a respective bottle.
  • the module 148 also evaluates the classification flag for each object, and based on the over size, under size, and over count set points set for the particular product, determines when to terminate filling each container.
  • the module 148 can be set to accept these without compensation, or to permit two additional "good" objects to be discharged into the respective bottle to compensate for the reject objects. If, on the other hand, a fourth reject is detected before the respective bottle is filled, i.e., before it reaches its count, a reject flag is generated to divert the rejected bottle into the reject lane 76 of the conveyor, as is described further below.
  • the module 148 transmits control signals to the DAP module 150 to successively close the gates discharging into the respective bottle, more specifically, once the object count for a respective bottle equals the fill number minus the number of guide paths discharging into the respective bottle (fill no. - no. of guide paths per bottle) , control signals are transmitted to sequentially close each gate upon discharging its next "good" object.
  • the module 148 transmits control signals to the DAP 118 to close each of the four guide paths upon discharging its next "good" object. Accordingly, after the 100th 5 object is discharged, all four guide paths are closed.
  • the module 148 instructs the DAP module 150 to initialize a "settling" timer to prevent actuation of the respective bottle actuator 84 until the last objects in the 10 respective count drop and settle into the bottle.
  • the module 148 also transmits bottle indexing and control commands to the DAP module 150 to automatically control bottle movement through the fill station 70.
  • the DAP module actuates the respective bottle actuator 84 to drive the respective bottle pusher 86 into its extended position. This pushes a new bottle 68 into
  • the DAP module 150 opens the respective gates 44 to fill the next bottle.
  • the DAP module does not retract the extended bottle actuator 84 until the other actuators are extended and ready to be retracted, so that all bottle actuators are
  • the counting and reject evaluation module 148 repetitively interfaces with the DAP module 150 to confirm that instructions have been followed. For example, if a control signal is transmitted to close a particular gate, and the DAP does not confirm that the gate has been closed within a predetermined time period, a fault signal is generated to investigate and/or correct the defective condition.
  • the module 148 transmits all control parameters to the DAP, including the object fill rate (primarily controlled during run mode by adjusting the hopper baffle 128), and all initialization values for initializing counters and taking action.
  • the module 148 also performs adaptive speed control by repetitively monitoring the object fill rate (or speed) of the apparatus based on the line scan data, e.g., the average number of objects filled per second per bottle, and transmits control signals to the DAP for adjusting the hopper baffle 128 to substantially maintain fill rate set points.
  • the DAP 118 is a real time, multi-tasking processor for controlling the digital and analog output components of the apparatus.
  • the DAP module 150 transmits to the status comparison module 144 safety and input evaluation information, e.g., sensor signals indicating that safety guards or other safety equipment is in place, signals transmitted by the hopper level sensor 124 indicating whether there is sufficient product in the hopper to run and/or complete a batch or job, and sensor signals indicating that bottles are received for filling in the entry path 72 of the conveyor.
  • the DAP module 150 also executes gate control signals and timing event signals received from the counting and reject evaluation module 148.
  • the DAP module also provides a continuous, feed-back control loop and is responsive to control signals transmitted by the module 148 to substantially maintain all set points.
  • the DAP module 150 temporarily stops operation of the feed tray vibrators 24, 26 and 28 to stop all movement of objects.
  • the DAP module also initiates a timer as each object is counted subsequent to the reject flag. Then, when no objects are counted for a predetermined period of time as set by the timer, all of the gates 44 are closed.
  • the DAP module then resets all bottle actuators 84 to their retracted position, so that second bottles 68 are received in front of each bottle actuator.
  • the module 148 and DAP module 150 then wait for any "good” filled bottles to clear the outlet sensor 80, and once the sensor signals are received indicating that all such "good” bottles are received in the outlet path 74 the diverter gate 78 is actuated into the reject position, as shown in dashed lines in FIG. 4.
  • the bottle actuator 84 corresponding to the reject bottle is then actuated into its extended position to push the reject bottle onto the outer lane of the conveyor so that it is in turn directed by the diverter gate 78 into the reject path 76.
  • the DAP module also initiates a fault timer.
  • the reject sensor 82 does not transmit a signal indicating passage of the reject bottle into the reject path within the period of the fault timer, a fault signal is generated and the run mode is automatically stopped. If, on the other hand, the outlet sensor 82 receives the reject bottle within the period of the fault timer, the run mode is initiated, i.e., the diverter gate 78 is returned to its run (or default) position, the fault timer is reset, all gates are opened, and the vibrators are turned on to continue filling the bottles.
  • the status and comparison module 144 repetitively selects status and comparison data from the DAP module 150, and transmits the same to the traffic control module 142 for display on the OIC 104.
  • Typical data transmitted by the module 144 includes the current number of bottles filled, the current fill rate, whether important components, such as the optical sensor 38 and conveyor 66 are functional, and whether any processor has faulted.
  • the module 144 therefore reads all inputs and outputs from the DAP module 150, compares the various signals, and conveys the information to the traffic control and serial communications module 142.
  • the module 142 organizes and controls the sequence of operations of the several code modules, and converts status information received from the status comparison module 144 for transmission to the OIC 104 on a non-interrupted basis.
  • the module 144 processes the information in bit patterns, and therefore the module 142 must convert the bit patterns to code for transmission to the OIC 104.
  • the CSC 108 also comprises a watchdog timer card 158 coupled to an emergency stop circuit 160 for terminating operation of the apparatus.
  • a watchdog timer card 158 coupled to an emergency stop circuit 160 for terminating operation of the apparatus.
  • the main software code loop i.e., code modules 142, 144, 148 and 150
  • the optical sensor and classifying object modules 152 and 146 respectively, each run a complete loop. If the main code is interrupted due to a fault condition, and does not reset within a time period set by the watchdog timer 158, the watchdog timer activates the emergency stop circuit
  • the first step (S2) is to set the operating parameters for the optical sensor to a first set ("set 1"), which is a list of internal variables for the optical sensor, including, for example, the reference voltage (VRef) , interrupt speed and filter number.
  • set 1 is a list of internal variables for the optical sensor, including, for example, the reference voltage (VRef) , interrupt speed and filter number.
  • the optical sensor 38 has several sets of operating parameters for usage depending upon the physical characteristics of the objects being processed, including a first set corresponding to relatively large objects, a second set corresponding to relatively small objects, a third set corresponding to objects exhibiting substantial reflection, and a fourth set for gel-type objects which are substantially translucent. Within practical limits, any desired number of such optical sensor parameters can be formulated and coded within the sensor.
  • the code loop for the classifying objects module 146 and optical sensor module 152 are initiated (S4) .
  • the DAP module 150 checks the level of product in the hopper 14 as indicated by the hopper level sensor 124, and compares the measured level to a preset minimum necessary to run the respective batch or job, as indicated by step S6. If the hopper level is too low, the OIC 104 instructs the operator to fill the hopper (S8), and if the hopper level is sufficient, the DAP opens the hopper baffle 128 to a preset minimum opening (S10) . The DAP then starts the vibrators 26 and 28 for the main feed tray 18 at a preset medium amplitude and object speed, as indicated by step S12. The hopper baffle 128 is then further opened to a preset, initial setting (S14), and the vibrator 24 for the prefeed tray 16 is started and set to a preset minimum amplitude and object speed (S16) .
  • the DAP module 150 then initiates a timer for "n" seconds (S18), and upon expiration of the time period the counting and evaluation module 148 confirms whether or not the optical sensor 38 is imaging objects (S20) . If no objects are seen, the DAP module 150 opens the hopper baffle 128 to the next increment to increase the flow of objects onto the feed trays (S22) . Then, once objects are imaged by the optical sensor 38, the counting and evaluation module 148 determines whether objects are visible in all guide paths 30, and whether the object speed is greater than a minimum average rate "x" per path, e.g., objects per minute, as indicated by step S24. If the answer to the S24 inquiry is "no", the hopper baffle 128 is opened to the next increment to increase the flow of objects onto the feed trays (S22) .
  • the module 148 determines whether the average object length (based on the number of scans, "NrScns") is greater or less than a preset value (S26) . If at least 25 objects are less than the preset value, the objects are too small for "set 1". The "set 2" optical parameters are therefore automatically selected and the learn mode is restarted (S28) . If, on the other hand, at least, 25 objects are greater than the preset value, "set 1" for the optical sensor parameters is correct (S30) .
  • the module 148 then assesses the spacing between objects for each guide path based on the number of scans (NrScns) without image data between consecutive objects (S32) in order to test for opacity, which can vary for gel-type or clear capsules, for example, and affect optical sensor readings.
  • the feed tray vibrators are adjusted to optimize object speed and spacing, and minimize object bounce to enhance scan repeatability.
  • the main feed tray vibrators 26 and 28 are set to a preset maximum amplitude and object speed (S38) .
  • the average object length (based on NrScns) and the number of consecutive pixels of image data logically OR'd (“NrPxls") is then recorded for 100 consecutive object samples for the entire array (S40) .
  • the amplitude of the vibrators 26 and 28 is then decreased by one step (S42), and the average object length (NrScns) and the number of consecutive pixels of image data (NrPxls) for the next 100 consecutive object samples is recorded again for the entire array (S44) .
  • the first predetermined value is 3 and the second predetermined value is 1.1, which, as will be recognized by those skilled in the art, may be modified as necessary to suit the requirements of a particular installation. If the result of the S46 inquiry is "no", then steps S42 through S46 are repeated until a "yes” is obtained, upon which optimization of the main feed tray vibrators is complete (S48) .
  • the prefeed tray vibrator 24 is then adjusted to further optimize the spacing between objects.
  • the average scan spacing for each guide path i.e., the average number of consecutive scans without image data is determined (S50) . If the average scan spacing for all guide paths is less than or equal to a preset value (S52), then vibrator optimization, i.e., object speed and spacing, is complete (S54). If the answer to the step S52 inquiry is "no", then the amplitude of the prefeed vibrator 24 is increased by one step to further decrease object spacing (S56) . If, however, the prefeed vibrator 24 is already at its maximum amplitude, then the opening of the hopper baffle 128 is increased by one increment
  • step S58 If the hopper baffle and prefeed vibrator are at the maximum settings, then the object spacing cannot be further decreased, and vibrator optimization is complete (S60) . If, however, the hopper baffle can be opened further or the amplitude of the prefeed vibrator can be increased, a timer is initiated for "n" seconds (S62), and step S52 is repeated until vibrator optimization is complete.
  • object size classification may be recorded for SPC ("statistical process control") purposes (S64).
  • SPC statistical process control
  • the vibrators 24, 26 and 28 are stopped, a timer is initiated for "x" seconds, and upon expiration of the timer the module 148 reads the scan data to determine if any objects are seen (S66) .
  • the object classification module 146 is started, and the vibrators are started and set to the maximum amplitude as recorded above (S68) .
  • the area (NrPxls) and length (NrScns) are sampled and recorded for 25 consecutive objects for each guide path (S70) .
  • FIGS. 8-13 several screen displays of the OIC 104 are illustrated in further detail.
  • FIG. 8 illustrates a summary of the learn mode for a particular object type (or product) , and indicates at the top the object name, e.g. , "No. 1 tablet", and the respective apparatus ("UnitNr") if there is more than one coupled to the OIC.
  • the OIC 104 contains a database of learn mode, product parameters, and like information pertaining to each product or object type desired, as is described further below, and therefore pads are provided for moving to corresponding screen displays for other objects and apparatus, along with pads to start, stop and display status conditions.
  • the learn mode screen also displays the following "Measurement data" for the respective object type: the current object count, the minimum area measured (“MinArea”) (“NrPxls”), the maximum area measured (“MaxArea”) (“NrPxls”), the lower area control limit (“LCLArea”), the upper area control limit (“UCLArea”), the maximum allowable speed (“MaxSpeed_per_Lane/Minute”) as set during the learn mode, the minimum object length measured (“MinNrScan”) , the maximum object length measured (“MaxNrScan”) , the lower length control limit (“LCLNrScan”) , and the upper length control limit (“UCLNrScan”) .
  • An operator is thus permitted to view various aspects of the measurement data as it is collected for quality control purposes.
  • an exemplary SPC screen display from the' OIC database which was generated during the learn mode for an object or product type called
  • the left-hand side of the screen illustrates the sample distribution of the area measurements, and the right-hand side illustrates the sample distribution of the length measurements made during learn mode.
  • the area and length measurements for each lane, the mean values, and the upper and lower control limits are illustrated in graphical format. Also illustrated are the maximum and minimum values generated for each measurement during learn mode.
  • the OIC 104 automatically sets the upper and lower control limits according to a formula, typically set by the product manufacturer (or packager) pursuant to quality control specifications.
  • the upper and lower control limits may each be equal to "x" times the standard deviation, wherein "x" is a predetermined number (e.g., 4).
  • a predetermined number e.g. 4
  • the upper and lower control limits may be adjusted as desired by "clicking" the cursor on the respective arrow, e.g., with a “mouse” or “trackball”, or by “clicking on” and moving the respective bar in the graphical portion and moving the bar to the desired value.
  • a typical screen from the OIC database displaying product (or object) parameters is illustrated.
  • the respective object name is displayed (“Aspirin 100 ct"), along with the count per bottle, the number of the machine (if there is more than one apparatus 10 coupled to the OIC), the bottle speed set by the operator (“Set Bottle Speed”), and the maximum permissible bottle speed (“Max Bottle Speed”), typically in bottles per minute (BPM) .
  • the maximum bottle speed for the particular object is set based on the maximum object speed set during the learn mode, e.g., objects per minute per guide path, the number of guide paths per bottle, and the desired object count for each bottle. If the operator attempts to set the bottle speed greater than the "Max Bottle Speed" the setting will default to the maximum allowed speed.
  • Pads are also provided to select the product (or object type) to be displayed, the type of bottle to receive the object, and the respective "quality profile”.
  • An exemplary "quality profile” is illustrated in FIG. 11, and in addition to providing pads for selecting other profiles from the database or generating new profiles, "Auto make Up Oversize” and “Auto Make Up Undersize” displays and control pads are provided.
  • the Auto Make up Oversize pad permits the operator to set the number of over size objects, i.e., over either upper control limit, UCL, that will be accepted in each container, and to instruct the apparatus as to whether it should "Make Up oversize,” i.e., add one object for each oversize object.
  • the "Auto Make Up Undersize” pad permits the operator to set the number of undersize objects, i.e., under either lower control limit, LCL, that will be accepted in each container, and to instruct the apparatus as to whether it should "Make up undersize", i.e., add one object for each undersize object.
  • the apparatus will accept one oversize object per bottle, and will not make up for (or add any good objects) for the oversize object permitted.
  • the apparatus will accept two undersize objects per bottle ("Accept" pad is designated “True” for the number "2"), and will make up for any undersize products, i.e., add one good object for each undersize object ("Make Up Undersize” pad is designated “True”).
  • the "Over Count” display includes an "Accept” pad to designate the number of overcount bottles that will be accepted, and a “Stop On Reject” pad is provided to designate whether the apparatus should automatically stop if a "reject" bottle is created.
  • the "Reject Auto Shutdown” display includes a "Consecutive Reject” pad to designate the number of consecutive reject bottles that will be permitted (in this example, 3), and the total number of reject bottles that will be permitted (in this example, 20) before the apparatus will be automatically shut down.
  • a "Run Screen” display is also provided for providing real-time, status information in both graphical and alphanumeric format while a job or batch is running.
  • Actual speed typically bottles per minute, "BPM”
  • Set Speed desired speed
  • Graphical and alphanumeric displays are also provided to show the rate at which each bottle is being filled (BOT1, BOT2, and BOT3) , the level of product or objects in the hopper 14, and the estimated time remaining before the hopper will be emptied.
  • a display is also provided to define the dimensions, e.g., length, width and height, for each bottle or container type.
  • the transportable housing and frame assembly 12 includes hydraulic actuators, which are controlled by the DAP 118 to adjust the level of the bottom edge of the chute relative to the conveyor 66 to ensure that there is adequate spacing within the filling station for each bottle type.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)

Abstract

On peut compter et emballer automatiquement dans des récipients (68) des objets séparés, tels que des comprimés ou des capsules, en les déversant d'une trémie (14) sur un plateau de préalimentation (16) à vibrations qui, à son tour, déverse les objets sur un plateau d'alimentation principal (18) à vibrations définissant une pluralité de voies (30) pour différencier les objets. Un détecteur optique (38) balaye de manière répétée les objets différenciés et génère des données sous forme d'images indiquant la longueur et la surface de l'objet. Une unité de commande (110) détermine la surface et la longueur de l'objet et génère un drapeau de classification pour chaque objet qui indique si l'objet est rejeté ou non. Une base de données de profils de qualité prédéterminés pour des types d'objets particuliers est également installée, et chaque profil peut comprendre une instruction destinée à l'unité de commande en vue de remplacer les objets rejetés. Une unité de commande attribue également chaque objet balayé à une voie et à un récipient respectifs, et compte le nombre d'objets dans chaque récipient.
PCT/US1995/009894 1994-08-04 1995-08-04 Appareil et procede de comptage et d'emballage automatiques d'objets separes WO1996004171A1 (fr)

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AU33604/95A AU3360495A (en) 1994-08-04 1995-08-04 Apparatus and method for automatically counting and packaging discrete objects

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US08/285,806 1994-08-04
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US08/285,806 US5463839A (en) 1994-08-04 1994-08-04 Apparatus for packaging a predetermined quantity of objects and a counting device therefor

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ITBO20120209A1 (it) * 2012-04-17 2013-10-18 Marchesini Group Spa Apparecchiatura di riempimento di contenitori per il riempimento di contenitori con articoli farmaceutici/parafarmaceutici
CN104859899A (zh) * 2015-04-17 2015-08-26 深圳市联星服装辅料有限公司 振动式纽扣计数机
CN106586088A (zh) * 2016-12-16 2017-04-26 浙江大成智能装备股份有限公司 一种用于电池钢壳的机器视觉计量检测装置及检测方法
CN108438379A (zh) * 2018-04-09 2018-08-24 李吉发 自动点数机
CN109635911A (zh) * 2018-11-28 2019-04-16 中山天聚自动化输送设备有限公司 蛋黄计数系统
CN110202921A (zh) * 2019-07-23 2019-09-06 青岛益青生物科技股份有限公司 装有计数定量装置的胶囊印字机
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IT201900012111A1 (it) * 2019-07-17 2021-01-17 Nuova Cesare Delpiano Soc Cooperativa Unita’ di gestione automatica del trasporto e del confezionamento di prodotti in genere e procedimento realizzato con questa unita’
CN110202921A (zh) * 2019-07-23 2019-09-06 青岛益青生物科技股份有限公司 装有计数定量装置的胶囊印字机
CN110202921B (zh) * 2019-07-23 2024-05-07 青岛益青生物科技股份有限公司 装有计数定量装置的胶囊印字机
US20220097878A1 (en) * 2020-09-25 2022-03-31 Express Scripts Strategic Development, Inc. Cleaner assembly for an automated dispensing device
US11787578B2 (en) * 2020-09-25 2023-10-17 Express Scripts Strategic Development, Inc. Cleaner assembly for an automated dispensing device

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