Automated prescription vial filling system

Abstract

A method and apparatus for dispensing drugs, wherein a patient's order of one or more prescriptions is automatically filled. Various drugs are stored in three or more filler lines. A vial size is assigned to each line. When a prescription is filled, it is automatically assigned to a line in view of the vial size requirements and processed accordingly. Provisions are made for the inability to fill a prescription or order. Subsequently, all of the patient's prescriptions are collected and made available as a single order.

I claim:  
     
       1. A system for automatically filling prescriptions comprising: 
       means for receiving a patient's order, said order comprising patient identification information and one or more prescriptions;  
       at least one prescription filling line including machines for automatically filling, labeling, and capping vials with drugs; 
       means for assigning one of said prescriptions to said  at least one prescription filling line for processing;  
       the at least one prescription filling line serving to automatically process the assigned prescription without human intervention and comprising:  
         vial filling means for filling at least one discrete vial with oral solid medication according to the prescription, said vial defining a re - closable vial opening and said medication being selected from a plurality of different bulk - form oral solid medications;    
       
         labeling means for placing a label including information on the vial;  
       
       
         capping means for closing the vial opening with a replaceable cap after filling; and 
       
         vial - transport means for automatically moving the vial about the filling, labeling and capping means and to a means for vial - receiving and sorting;    
         the receiving and sorting  means for  receiving vials from said prescription filling line and for  automatically sorting said vials according to patient orders; and  
       means for automatically collecting vials pertaining to one patient's order.  
     
     
       2. The system of  claim 1 , wherein said means for receiving vials from said filling line and for sorting said vials comprises an accumulator positioned at a terminus of said filling line operative to position a vial received from said filling line in a designated accumulator area. 
     
     
       3. The system of  claim 1 , wherein said means for collecting vials comprises a conveyor disposed adjacent the terminus of said filling line and selectable receptacles carried by said conveyor, said selectable receptacles operative to receive therein vials. 
     
     
       4. The system of  claim 3  further comprising means for removing said receptacles from said conveyor and for directing said receptacles to one of a plurality of spurs. 
     
     
       5. A system for automatically filling prescriptions, comprising: 
       a controller for receiving a patient order, said order comprising patient identification information and at least one prescription;  
       automated prescription filling apparatus operatively controlled by the controller for automatically processing the order without human intervention comprising:  
       at least one filling line conveyor;  
       a device for storing at least one empty vial associated with said filling line conveyor, each vial defining a re- closable vial opening ;  
       an unscrambler disposed along said filling line conveyor for retrieving said vial and to position said vial on said filling line conveyor;  
       a filler positioned along said filling line conveyor downstream of said unscrambler for placing drugs in said vial in accordance with said prescription  and including plural canisters each for storing a discrete type of oral solid medication in bulk, the filler directing selected medication into the vial in accordance with said order;  
       a labeler positioned along said filling line conveyor downstream of said filler for applying a label to said vial;  
       a capper positioned along said filling line conveyor downstream of said filler for securing a replaceable cap on  over the opening of said vial;  
       an accumulator positioned at a downstream end of said filling line conveyor for receiving said vial;  
       a sorting conveyor disposed adjacent said accumulator;  
       at least one removable receptacle carried on said sorting conveyor; and  
       a device for transferring said vial from said accumulator to said receptacle.  
     
     
       6. The system of  claim 5 , wherein said receptacle is coded, and said system includes a reader disposed adjacent said sorting conveyor so that said reader can read a code on said receptacle, said reader being in communication with said controller so that said receptacle can be correlated with a particular order. 
     
     
       7. The system of  claim 5 , further including at least one spur adjacent said sorting conveyor and a device for transferring said receptacle from said sorting conveyor to said spur. 
     
     
       8. The system of  claim 7 , comprising a plurality of spurs disposed adjacent said sorting conveyor and said device for transferring said receptacle to a spur selectively transfers said receptacle to any of said spurs. 
     
     
       9. The system of  claim 6 , including a plurality of filling line conveyors, each filling line conveyor having associated therewith a device storing at least one vial, an unscrambler, a filler, a labeler, a capper and an accumulator; said sorting conveyor running adjacent said accumulator. 
     
     
       10. The system of  claim 9 , wherein said device storing at least one vial stores a vial of a different volume. 
     
     
       11. A method for filling a prescription comprising the steps of: 
       waiting for presentation of a patient order, said order comprising one or more prescriptions and patient identification information;  
       determining whether said order is valid;  
       rejecting an invalid order;  
       placing said order in a first-in, first-out list if said order is valid;  
       acknowledging placement of said order on said first-in, first-out list;  
       assigning each prescription in said order to a separate filling process;  
       assigning a collection receptacle to said order, receiving said filled prescriptions from said filling process;  
       determining a vial size required to fill a prescription;  
       determining whether filling the prescription will deplete a drug supply below a minimum;  
       determining whether filling the prescription will fully deplete the drug supply; and terminating the process if filling the prescription will fully deplete the drug supply.  
     
     
       12. A method for filling prescriptions comprising the steps of: 
       providing a patient order, said order comprising patient identification data and at least one prescription;  
       assigning each prescription in said order to a separate filling process;  
       assigning a collection receptacle to said order, said receptacle receiving filled prescriptions from said filling process;  
       determining a vial size required to fill a prescription;  
       determining whether filling the prescription will deplete a drug supply below a minimum;  
       generating a re-fill request is  if filling the prescription will deplete the drug supply below the minimum;  
       determining whether the prescription will fully deplete the requisite drug supply; and  
       terminating the process if filling the prescription will fully deplete the drug supply.  
     
     
       13. A system for automatically filling prescriptions, comprising: 
       at least one automated filling line including devices for automatically filling a vial with prescribed drugs, labelling  labeling said vial, and capping said vial;  without human intervention comprising:  
         a vial - transport mechanism positioned to transport the vial to filler apparatus and receive the filled, capped vial from a capper;    
         the filler apparatus is positioned to receive the vial from the vial - transport mechanism and includes plural canisters each for storing a discrete type of oral solid medication in bulk, the filler apparatus directing the prescribed drugs into the vial from at least one canister;    
       
         labeler apparatus positioned to receive the vial, the labeler including labeling apparatus for applying a label with information to the vial;  
       
       
         the capper is positioned to receive the filled vial, the capper including capping apparatus for applying a replaceable cap on the vial;  
       
       a sorting system disposed at a terminal of said filling line for receiving vials therefrom  said vial from the vial- transport mechanism  and automatically transporting collections of said vials, each collection pertaining to a particular patient; and  
       a control system for controlling said filling line in  and said sorting system.  
     
     
       14. The prescription filling system of  claim 13 , wherein said sorting system includes a plurality of receptacles, each receptacle being coded with information so that said receptacles can be temporarily correlated with a particular patient. 
     
     
       15. The prescription filling system of  claim 13 , wherein said control system includes a plurality of lists to which prescription information is successively transferred during processing of a prescription. 
     
     
       16. The method of  claim 11  including the further step of, if the requisite drug supply is available, automatically filling the prescription.  
     
     
       17. The method of  claim 12  including the further step of, if the requisite drug supply is available, automatically filling the prescription.  
     
     
       18. A system for automatically filling patient prescription orders, the system comprising: 
       
         a control system for receiving a patient's prescription order, said order including patient identification and prescription information, and for controlling apparatus for automatically filling at least one prescription corresponding to the patient's prescription order;  
       
         at least one prescription filling line operatively controlled by the control system including machine structure for automatically filling and labeling at least one discrete vial without human intervention in accordance with the patient's prescription order, said at least one vial having a surface and defining a re - closable vial opening and the filling line machine structure including:    
         a vial - transport mechanism configured to automatically transport the at least one vial between at least a first position in which the empty vial is received by the vial - transport mechanism, another position in which the empty vial is transported to vial - filler apparatus and a further position in which the filled vial is transported to a vial accumulator;    
         the vial - filler apparatus is positioned to receive the empty vial transported by the vial - transport mechanism and includes plural canisters each for storing a discrete type of oral solid medication in bulk, the vial - filler automatically dispensing oral solid medication from at least one of said canisters and into said vial in accordance with the prescription order; and    
         vial - labeler apparatus positioned with respect to the filling line and including labeler apparatus configured to place a label including information on the vial surface;    
         the vial accumulator being operatively controlled by the control system and positioned to receive the at least one discrete vial from the filling line vial - transport mechanism, the accumulator including vial receiving and sorting structure, said sorting structure automatically sorting the at least one vial according to the prescription order; and    
       
         a vial collector operatively controlled by the control system and positioned with respect to the accumulator to receive the at least one sorted vial from the accumulator pertaining to the patient's prescription order.  
       
     
     
       19. The system of  claim 18  including two prescription filling lines.  
     
     
       20. The system of  claim 19  wherein the control system assigns the prescription to the filling line capable of most efficiently filling the discrete vials with the prescribed drugs.  
     
     
       21. The system of  claim 18  wherein the filling line further includes vial capper apparatus positioned to receive the filled vial and automatically apply a replaceable cap across the vial opening.  
     
     
       22. A system for automatically filling patient prescription orders, the system comprising: 
       
         a control system for receiving a patient's prescription order and for controlling apparatus for automatically filling at least one prescription corresponding to the patient's prescription order;  
       
         at least one filling line operatively controlled by the control system including machine structure for automatically filling and labeling at least one discrete vial according to the patient's prescription order without human intervention, the vial defining a re - closable vial opening and having at least one vial surface, and the filling line machine structure including:    
         a vial - transport mechanism configured to automatically transport the at least one vial between at least a first position in which the empty vial is received by the vial - transport mechanism, another position in which the empty vial is transported to vial - filler apparatus and a further position in which the filled vial is transported to a filling line terminal end;    
         the vial - filler apparatus is positioned to receive the empty vial transported by the vial - transport mechanism and includes plural canisters each for storing a discrete type of oral solid medication in bulk, the vial - filler automatically dispensing oral solid medication from at least one of said canisters and into said vial in accordance with the prescription order; and    
         vial - labeler apparatus positioned with respect to the filling line and including labeler apparatus configured to place a label including information on the vial surface;    
         a system disposed at the terminal end of the filling line operatively controlled by the control system including machine structure configured to receive the at least one discrete, filled vial from the vial - transport mechanism and automatically collect said at least one vial corresponding to the patient's order.    
     
     
       23. The system of  claim 22  including two prescription filling lines.  
     
     
       24. The system of  claim 22  wherein the filling line further includes vial capping apparatus positioned to receive the at least one filled vial and automatically apply a replaceable cap over the vial opening.  
     
     
       25. A method for automatically filling patient prescription orders without human intervention comprising the steps of: 
       
         providing a patient's prescription order, said order comprising patient identification and prescription data, to a control system for controlling a vial filling line and apparatus for collecting vials corresponding to the patient's prescription order;  
       
       
         providing at least one filling line operatively controlled by the control system including machines for automatically transporting, filling and labeling discrete vials corresponding to the patient's prescription order, each of said vials having at least one surface defining a vial opening;  
       
       
         providing at least one machine, operatively controlled by the control system, for automatically collecting the filled, labeled discrete vials corresponding to the patient's order;  
       
       
         automatically transporting at least one empty vial to the filling machine based on at least one command from the control system;  
       
         automatically filling the at least one discrete vial with the filling machine, said filling machine automatically placing bulk - form medication in said at least one vial corresponding to the patient's prescription order based on at least one command from the control system;    
       
         during or after the filling step, automatically placing a label on the surface of said at least one vial based on at least one command from the control system;  
       
       
         automatically transporting said filled, labeled at least one vial to the collecting machine based on at least one command from the control system; and  
       
       
         automatically collecting filled, labeled vials corresponding to the patient's prescription order based on at least one command from the control system.  
       
     
     
       26. The method of  claim 25  further comprising the step of before the filling step, receiving a plurality of unfilled vials for selective transport to the filling line.  
     
     
       27. The method of  claim 26  further comprising the step of before the filling step, transporting a collection of the plurality of unfilled vials to the filling line wherein the collection pertains to a particular patient.  
     
     
       28. The method of  claim 25  further comprising the step of providing at least two filling lines.  
     
     
       29. The method of  claim 28  further comprising the step of before the filling step, assigning each prescription in said order to the filling line capable of most efficiently filling the patient's order.  
     
     
       30. The method of  claim 25  further comprising the steps of: 
       
         providing at least one machine, operatively controlled by the control system, for automatically capping the at least one filled, labeled discrete vial corresponding to the patient's prescription order; and  
       
         after the filling step, automatically capping the re - closable vials with a reusable cap placed over the vial opening based on at least one command from the control system.    
     
     
       31. A method for automatically filing patient prescription orders with medication in at least one discrete vial defining a re- closable vial opening and having a vial surface, said medication corresponding to a person's prescription order and for automatically collecting the at least one filled, labeled vial corresponding to the person's prescription order comprising the steps of:    
       
         providing a person's prescription order to a control system for processing said prescription order and for controlling a filling line comprising automated apparatus for transporting, filling and labeling discrete vials and for controlling apparatus for collecting the filled, labeled vials corresponding to the prescription order;  
       
       
         providing the filling line comprising automated apparatus for transporting, filling and labeling discrete vials and apparatus for collecting the filled, labeled vials corresponding to the prescription order;  
       
       
         providing at least one command from the control system to the automated vial transporting apparatus whereby at least one empty vial is transported to the filling and labeling apparatus;  
       
       
         providing at least one command from the control system to the automated apparatus for filling and labeling whereby the at least one discrete vial is, in no particular order, automatically filled with medication corresponding to the patient's prescription order and automatically labeled with patient prescription information;  
       
         providing at least one command from the control system to the automated vial transporting apparatus whereby the at least one filled, labeled vial is transported to the automated vial - collecting apparatus; and    
         providing at least one command from the control system to the automated vial - collecting apparatus whereby the at least one filled, labeled vial is collected corresponding to the patient's prescription order.    
     
     
       32. The method of  claim 31  wherein apparatus for automatically capping a filled, labeled discrete vial is provided and further including the step of providing at least one command from the control system to the automated capping apparatus whereby the at least one filled vial is capped with a reusable cap placed over the vial opening.  
     
     
       33. The method of  claim 31  further including the step of providing at least two filling lines controlled by the control system.  
     
     
       34. The method of  claim 33  further including the step of, before the filling step, assigning each prescription in said patient prescription order to the filling line capable of most efficiently filling the patient prescription order.