Devices for dispensing objects useful in system and method for dispensing

1. A device for singulating open-ended objects, the device comprising:

a housing configured to retain a plurality of open-ended objects, the housing having an open lower end;

an outer ring positioned below the housing;

a drum positioned within the outer ring to form a drum assembly, the drum including a hub having a substantially circular wall and a plurality of wings that extend radially outwardly from the wall toward the outer ring, the hub, wings and outer ring forming a plurality of gaps;

a mounting structure with an exit aperture fixed relative to the housing; and

a rotary drive unit mounted to the drum that rotates the drum about an axis of rotation;

wherein the mounting structure further comprises a pre-staging station fixed relative to the housing and positioned below the exit aperture, and wherein the pre-staging station is positioned such that the dispensing of an object from the gap through the exit aperture causes the object to reside in the pre-staging station;

wherein the pre-staging station is positioned a distance below the exit aperture such that an object residing in the pre-staging station has a portion that extends above the exit aperture and a portion that extends below the exit aperture.

2. The device defined in claim 1 , wherein the drum assembly is mounted such that the axis of rotation forms an angle of between about 40 and 50 degrees relative to horizontal.

3. The device defined in claim 1 , wherein the drum includes a generally cone-shaped section that is positioned above the wall of the hub.

4. The device defined in claim 1 , wherein the drum assembly further includes at least one agitation finger that extends from the hub.

5. The device defined in claim 1 , wherein the outer ring includes a radially inwardly-extending rim, the rim being sized so that an open-ended object of a predetermined size is able to enter one of the gaps if the open end of the object is facing the hub, but is unable to enter any of the gaps if the closed end of the object is facing the hub.

6. The device defined in claim 1 , wherein the mounting structure is a mounting scaffold within which the outer ring resides.

7. The device defined in claim 1 , further comprising a separating structure mounted on the outer ring and positioned above the exit aperture at a height selected to enable a first object to pass beneath the separating structure and drop through the exit aperture but prevent a second object from dropping through the exit aperture.

8. The device defined in claim 7 , wherein the separating structure comprises one of a plurality of screws and a separating blade.

9. The device defined in claim 7 , wherein the wings include generally horizontal slots, and wherein the separating structure is positioned to extend into the horizontal slot of a wing positioned adjacent the separating structure as the drum rotates.

10. A device for singulating round open-ended objects, the device comprising:

a housing configured to retain a plurality of round open-ended objects, the housing having an open lower end;

an outer ring positioned below the housing;

a drum positioned within the outer ring to form a drum assembly, the drum including a hub having a substantially circular wall, the hub and outer ring forming at least one gap therebetween;

a mounting structure fixed relative to the housing, the mounting structure including a floor with an exit aperture defined therein;

a rotary drive unit mounted to the drum that rotates the drum about an axis of rotation; and

a separating structure fixedly mounted to the outer ring and positioned above the exit aperture at a height selected such that, as the drum rotates, a first round object can pass beneath the separating structure and drop through the exit aperture as a second round object positioned above the first round object passes above the separating structure, thereby preventing the second round object from dropping through the exit aperture;

wherein the mounting structure further comprises a pre-staging platform fixed relative to the housing and positioned below the exit aperture, and wherein the pre-staging station is positioned such that the dispensing of an object from the gap through the exit aperture causes the object to reside in the pre-staging station;

wherein the pre-staging station is positioned a distance below the exit aperture such that an object residing in the pre-staging station has a portion that extends above the exit aperture and a portion that extends below the exit aperture.

11. The device defined in claim 10 , wherein the drum assembly is mounted such that the axis of rotation forms an angle of between about 40 and 50 degrees relative to horizontal.

12. The device defined in claim 10 , wherein the drum includes a generally cone-shaped section that is positioned above the wall of the hub.

13. The device defined in claim 10 , wherein the drum assembly further includes at least one agitation finger that extends from the hub.

14. The device defined in claim 10 , wherein the outer ring includes a radially inwardly-extending rim, the rim being sized so that an open-ended object of a predetermined size is able to enter the gap if the open end of the object is facing the hub, but is unable to enter the gap if the closed end of the object is facing the hub.

15. A method of singulating round open-ended objects residing in a housing, comprising the steps of:

providing a drum assembly comprising an outer ring positioned below the housing and a rotatable drum positioned within the outer ring, the drum including a hub having a substantially circular wall, the hub and outer ring forming at least one gap therebetween, the drum assembly further including a separation structure fixedly mounted on the outer ring and extending radially inwardly, the separation structure being positioned such that, as the drum rotates, a first round object can pass below the separation structure as a second round object positioned above the first round object passes above the separation structure, the drum assembly being mounted on a mounting structure having a floor with an exit aperture defined therein;

feeding the drum assembly with round objects; and

rotating the drum about an axis of rotation such that a round object drops into a gap and passes below the separation structure and into the exit aperture;

wherein, upon exiting the drum assembly, the object is received on a pre-staging platform positioned below the exit aperture, wherein the pre-staging station is positioned such that the dispensing of an object from the gap through the exit aperture causes the object to reside in the pre-staging station, and wherein the pre-staging station is positioned a distance below the exit aperture such that an object residing in the pre-staging station has a portion that extends above the exit aperture and a portion that extends below the exit aperture.

16. The method defined in claim 15 , wherein the objects have a diameter of between about 1.15 and 1.90 inches.

17. The method defined in claim 16 , wherein the distance between the separation structure and the prestaging platform is between about 1.9 and 2.2 inches in height.

18. The method defined in claim 15 , wherein the objects have a diameter of between about 2.0 and 2.4 inches.

19. The method defined in claim 18 , wherein the distance between the separation structure and the floor is between about 2.3 and 2.6 inches in height.

20. The method defined in claim 15 , wherein the axis of rotation is between about 40 and 50 degrees relative to horizontal.

21. The method defined in claim 15 , wherein the object on the pre-staging platform is a first object, and wherein repeating the rotating step causes a second object to exit a gap onto the pre-staging platform and the first object to drop from the pre-staging platform.

22. The method defined in claim 15 , wherein the objects are caps for pharmaceutical vials.