FIELD OF THE DISCLOSURE
The present disclosure relates to an adjustable frame mount for a process unit, and more particularly to structures for obtaining alignment between a process unit and a modular machine frame.
BACKGROUND OF THE INVENTION
Cup filling and sealing apparatuses are used to fill and contain comestibles in liquid or semi-liquid form within a cup. Various steps of packaging a comestible within a cup are performed in series. Such steps may include filling, sealing, and capping the cup. Some existing cup filling and sealing apparatuses include a conveyor for passing cups between modules of the cup filling and sealing apparatus. Machines for completing each of the steps can be mounted on a frame. However, as the conveyor passes the cup between each machine, it is important to locate each machine at a desired position.
SUMMARY OF THE INVENTION
The present invention provides, in one aspect, a modular processing machine including a plurality of process units for completing a series of sequential tasks on a work piece conveyed through the modular processing machine. The modular processing machine comprises a module including a mounting plate, a rail extending a longitudinal axis, the rail being connected to the mounting plate, and a first longitudinal alignment plate fastened to the rail at a predetermined longitudinal distance from the mounting plate. The modular processing machine further comprises a jack screw connected to the first longitudinal alignment plate. The modular processing machine further comprises a process unit including a second longitudinal alignment plate connected to the jack screw and supported by the rail, the process unit being mounted to the second longitudinal alignment plate and being operable to perform a task associated with the module. The jack screw is operable to translate the process unit along the rail between a first longitudinal position relative to the first longitudinal alignment plate and a second longitudinal position displaced from the first longitudinal position.
The present invention provides, in another aspect, a modular processing machine including a plurality of process units for completing a series of sequential tasks on a workpiece conveyed through the modular processing machine. The modular processing machine comprises a first module including a first rail extending along a longitudinal axis, the first rail having a first axial end, and a first longitudinal alignment plate fastened to the first rail at a predetermined longitudinal distance from the first axial end. The modular processing machine further comprises a jack screw connected to the first longitudinal alignment plate. The modular processing machine further comprises a first processing unit mounted within the first module on the first rail, the first process unit being operable to perform a first task associated with the first module, the first process unit including a second longitudinal alignment plate connected to the jack screw and supported by the first rail. The modular processing machine further comprises a second module including a second rail extending coaxially with the longitudinal axis, the second rail having a second axial end connected to the first axial end. The second module further comprises a second process unit operable to perform a second task associated with the second module, the second process unit being mounted within the second module on the second rail. The jack screw is operable to shift the second longitudinal alignment plate relative to the first longitudinal alignment plate in a longitudinal direction between a first longitudinal position relative to the first axial end and a second longitudinal position displaced from the first longitudinal position.
The present invention provides, in another aspect, a modular processing machine including a plurality of process units for completing a series of sequential tasks on a work piece conveyed through the modular processing machine. The modular processing machine comprises a module including a mounting plate and a rail extending along a longitudinal axis, the rail being connected to the mounting plate. The modular processing machine further comprises a first longitudinal alignment plate fastened to the rail at a predetermined longitudinal distance from the mounting plate and a jack screw connected to the first longitudinal alignment plate. The modular processing machine further comprises a process unit including a second longitudinal alignment plate connected to the jack screw and supported by the rail, the process unit being mounted to the second longitudinal alignment plate and being operable to perform a task associated with the module. The jack screw is operable to translate the process unit along the rail between a first longitudinal position relative to the first longitudinal alignment plate and a second longitudinal position displaced from the first longitudinal position.
The present invention provides, in another independent aspect, a modular processing machine including a plurality of process units for completing a series of sequential tasks on a workpiece conveyed through the modular processing machine. The modular processing machine comprises a first module including a first rail extending along a longitudinal axis, the first rail having a first axial end. The first module further includes a first longitudinal alignment plate fastened to the first rail at a predetermined longitudinal distance from the first axial end and a jack screw connected to the first longitudinal alignment plate. The first module further includes a first process unit mounted within the first module on the first rail, the first process unit being operable to perform a first task associated with the first module, the first process unit including a second longitudinal alignment plate connected to the jack screw and supported by the first rail. The modular processing machine further comprises a second module including a second rail extending coaxially with the longitudinal axis, the second rail having a second axial end connected to the first axial end, and a second process unit operable to perform a second task associated with the second module, the second process unit mounted within the second module on the second rail. The jack screw is operable to shift the second longitudinal alignment plate relative to the first longitudinal alignment plate in a longitudinal direction between a first longitudinal position relative to the first axial end and a second longitudinal position displaced from the first longitudinal position.
Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a modular machine system.
FIG. 2 is a front view of the modular machine system of FIG. 1.
FIG. 3 is an enlarged perspective view of the modular machine system of FIG. 1 taken along section line 3-3 in FIG. 1.
FIG. 3A is a perspective view of a mounting plate of the modular machine system of FIG. 1 showing the outwardly facing side of the mounting plate.
FIG. 3B is a perspective view of the mounting plate of the modular machine system of FIG. 1 showing the inwardly facing side of the mounting plate.
FIG. 3C is an end view of the mounting plate of the modular machine system of FIG. 1 showing the inwardly facing side of the mounting plate.
FIG. 3D is an end view of the mounting plate of the modular machine system of FIG. 1 showing the outwardly facing side of the mounting plate.
FIG. 4 is a side view of the modular machine system of FIG. 1.
FIG. 5 is a cross-sectional view of the modular machine system of FIG. 1 taken along section line 5-5 in FIG. 4.
FIG. 6 is an enlarged cross-sectional view of the modular machine system of FIG. 1 taken along section line 6-6 in FIG. 5.
FIG. 7 is an enlarged cross-sectional view of the modular machine system of FIG. 1 taken along section line 7-7 in FIG. 4
FIG. 8 is an enlarged side view of the modular machine system of FIG. 1 taken along section line 8-8 in FIG. 2.
FIG. 9 is a side view of an infeed subassembly mounted within a module of the modular machine system of FIG. 1.
FIG. 10 is a side view of a dosing subassembly mounted within a module of the modular machine system of FIG. 1.
FIG. 11 is a side view of a sealing subassembly mounted within a module of the modular machine system of FIG. 1.
FIG. 12 is a side view of a discharge subassembly mounted within a module of the modular machine system of FIG. 1.
FIG. 13 is a perspective view of a vacuum pull down station of the infeed subassembly of FIG. 9.
FIG. 14 is a side view of the vacuum pull down station of FIG. 13.
FIG. 15 is a cross-sectional view of the modular machine system taken along section line 15-15 in FIG. 4.
FIG. 16 is another top perspective view of the modular machine system of FIG. 1.
FIG. 17 is a bottom perspective view of the modular machine system of FIG. 1.
FIG. 18 is an enlarged bottom perspective view of the modular machine system of FIG. 17 taken along section line 18-18 in FIG. 17.
FIG. 19 is an enlarged top perspective view of a jack screw of the modular machine system taken along section line 19-19 in FIG. 16.
FIG. 20 is an exploded view of the jack screw of the modular machine system of FIG. 19.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
FIG. 1 illustrates a cup filling and sealing apparatus 10 which is subdivided into three modules 10a, 10b, and 10c and supported by a work surface W. Each module 10a-10c includes a frame 14. Each frame 14 further comprises rails 18 which operatively align the three modules 10a-10c. The rails 18 support at least one functional process unit 24. Each rail 18 extends parallel to a longitudinal axis 20 defined by the center of one of the rails 18 such that the rails 18 of each of the three modules 10a-10c are aligned axially along the longitudinal axis 20. As will be discussed below, the interconnection of the modules 10a-10c through the rails 18 retains the alignment of each module 10a-10c such that the process units 24 mounted on the rails 18 are mounted in an aligned and predetermined location and orientation on the rails 18.
The functional process units 24 of the illustrated apparatus 10 relate to operations for a cup filling and sealing process for filling and sealing comestibles within a cup (not shown). However, the modules 10a-10c, frames 14, and rails 18 may be used in other contexts.
As markets change and user needs adapt, functions may need to be added or removed from the apparatus 10. For example, the apparatus 10 may be expanded to include an additional module 10d having a process unit 24 capable of disinfecting the cup. In some situations, it is important that the apparatus 10 has each functional process unit 24 installed adjacent an existing functional process unit 24. For example, an exemplary process unit 24 operable to apply comestibles to the cup may need to be located adjacent another exemplary process unit 24 operable to apply a cap to the cup to protect the comestibles from the environment. In some constructions, the apparatus 10 is self-contained in a relatively small package which can be readily transported to and positioned adjacent any one of several sources of comestibles being packaged.
The apparatus 10 allows for fully customizable layout of the module 10a-10c and permits various different functional process units 24 to be mounted within each module 10a-10c for completing various tasks related to cup filling and sealing. As a result, the number of repeated parts in the apparatus 10 is increased, and the number of unique parts is decreased. Individual modules 10a-10c can be assembled, tested, and shipped to the end user quickly and economically. The modules 10a-10c can be connected at a manufacturing site and shipped to the end user. Similarly, individual functional process units 24 can be assembled, tested, and shipped to the user quickly and economically for connection to a module 10a-10c at the site of the apparatus 10. Further, the end user is able to disassemble parts of the apparatus 10 and rebuild it in a different configuration, i.e., with a different particular arrangement of the modules 10a-10c (or additional modules not shown herein).
In the illustrated embodiment of FIG. 1, each frame 14 is generally in the form of a rectangular prism. The frame 14 has a length along the longitudinal axis 20, a width along a lateral axis 21 perpendicular to the longitudinal axis 20, and a height along a vertical axis 22 perpendicular to both the longitudinal axis 20 and the lateral axis 21. Each frame 14 includes a plurality of columns 26 (e.g., four columns) extending parallel to the vertical axis 22 from a lower end 26a to an upper end 26b, longitudinal members 30 extending parallel to the longitudinal axis 20 and connecting adjacent columns 26 along the longitudinal axis 20 from an upstream end 30a to a downstream end 30b, and lateral members 34 extending between adjacent columns 26 parallel to the lateral axis 21 from a first lateral end 34a to a second lateral end 34b. The upstream end 30a and the downstream end 30b also generally define an upstream end 30a and downstream end 30b of the module 10a. The illustrated embodiment includes two longitudinal members 30 and two lateral members 34 located adjacent the lower end 26a and the upper end 26b to interconnect each of the columns 26. In the illustrated embodiment, the lower ends 26a of the respective columns are supported on the work surface W by respective feet 26c. In other constructions, the frames 14 or portions thereof are modified to take other forms so as to change the various dimensional aspect ratios, the number or shape of frame members, and/or the placement thereof.
As shown in FIG. 5, the columns 26 of the first module define a periphery 38a of the rectangular prism-shaped frame 14 of the first module 10a. The periphery 38a of the frame 14 of the first module 10a does not interfere with a periphery 38B of the frame 14 of the second module 10b. In fact, the periphery 38a of the first module 10a is spaced from the periphery 38B of the second module 10b. As illustrated in FIG. 6, the columns 26 of the first module 10a have an outer surface 42a that is axially located at a position along the longitudinal axis 20 spaced from the columns 26 of the second module 10b. Similarly, the columns 26 of the second module 10b have an outer surface 42b that is axially located at a position along the longitudinal axis 20 spaced from the columns 26 of the first module 10a.
With reference to FIGS. 5 and 6, each column 26 has a cross sectional profile 46 taken perpendicular to the vertical axis 22 that is a C-channel. Each column 26 has an inwardly facing channel arm 50, an outwardly facing channel arm 54, and a channel body 60 spanning the channel arms 50, 54. In the frame 14, the inwardly facing channel arm 50 faces the longitudinal center of the frame 14. In the frame 14, the outwardly facing channel arm 54 faces away from the longitudinal center of the frame 14. In the frame 14, adjacent columns 26 in the lateral direction (i.e., columns aligned along a common lateral axis 21) have channel bodies 60 which face each other. In the frame 14, adjacent columns 26 in the longitudinal direction (i.e., columns aligned parallel with respect to each other along the longitudinal axis 20) have respective channel arms 50, 54 which face each other. The channel body 60 is in a plane defined by the longitudinal axis 20 and the vertical axis 22. The channel arms 50, 54 are in separate planes defined by the lateral axis 21 and the vertical axis 22. As such, the channel arms 50, 54 extend laterally (i.e., perpendicularly from the longitudinal axis 20).
As illustrated in FIG. 3, the frame 14 further comprises a guard door 61 located on a lateral side of the frame 14 corresponding with the first lateral end 34a. The guard door 61 is connected to the frame 14 by a hinge 61a. As such, the guard door 61 is pivotable relative to the frame 14 to permit or restrict access to the interior of the frame 14. As user may pivot the guard door 61 by a handle 61b located on an opposite side of the guard door 61 as the hinge 61a.
With continued reference to FIG. 3, the frame 14 of the module 10a further comprises mounting plates 62 connected to adjacent columns 26 in the lateral direction (i.e., columns aligned by a common lateral axis 21). Each frame 14 includes an upstream mounting plate 62a and a downstream mounting plate 62b. The upstream mounting plate 62a is located adjacent the upstream end 30a of the longitudinal members 30, and the downstream mounting plate 62b is located adjacent the downstream end 30b of the longitudinal members 30.
FIGS. 3A-3D illustrate one of the mounting plates 62 in detail. The mounting plate 62 includes an inwardly facing side 66 which faces the center of the frame 14 (i.e., towards the center of the frame 14 in the longitudinal direction along the longitudinal axis 20) and an outwardly facing side 70 which faces away from the center of the frame 14 (i.e., away from the center of the frame 14 in the longitudinal direction along the longitudinal axis 20). The mounting plate 62 includes a number of voids or cutouts 74 configured to reduce the weight of the mounting plate 62 and permit passage of objects through the cutouts 74.
With continued reference to FIGS. 3A-3D, the mounting plate 62 includes four rail holes 78 in the form of through holes passing through the inwardly facing side 66 to the outwardly facing side 70. In the illustrated embodiment, the rail holes 78 are counterbored rail holes 78 with counterbore surfaces 82 on the inwardly facing side 66. In the illustrated embodiment, the rail holes 78 are parallel to the longitudinal axis 20. The counterbore surfaces 82 are perpendicular to the longitudinal axis 20. In the illustrated embodiment, the rail holes 78 are positioned in a rectangular array along a plane that extends parallel to the vertical axis 22 and the lateral axis 21. The rail holes 78 may be otherwise located in the mounting plate 62 so long as they are parallel to the longitudinal axis 20.
With continued reference to FIGS. 3A-3D, the mounting plate 62 includes four column holes 86 configured for attaching the mounting plate 62 to two adjacent columns 26 in the lateral direction (i.e., columns at a common longitudinal position and spaced apart parallel to the lateral axis 21). In the illustrated embodiment, the column holes 86 are also positioned in a rectangular array. In the illustrated embodiment, the column holes 86 are located more laterally spread apart than the rail holes 78, but otherwise at a same common height relative to the work surface W.
As illustrated in FIG. 6, fasteners 94 extend through the column holes 86 to connect the mounting plate 62 to the channel arms 50, 54 of the each of the two adjacent columns 26 in the lateral direction (i.e., columns at a common longitudinal position and spaced apart parallel to the lateral axis 21). In the illustrated embodiment, the fasteners 94 extend through both of the channel arms 50, 54 along the longitudinal direction. As such, the mounting plate 62 is secured to the frame 14 within the periphery 38a of the frame 14 of the first module 10a. Additionally, when mounted to the frame 14, the mounting plate 62 is generally planar with a plane defined by the vertical axis 22 and the lateral axis 21.
With continued reference to FIG. 6, each of the fasteners 94 include a first bolt 94a and a second bolt 94b on either longitudinal side of the mounting plate 62. Each fastener 94 may include an isolator 94c positioned longitudinally between the first bolt 94a and the mounting plate 62. The fastener 94 may further include another isolator 94c positioned longitudinally between the second bolt 94b and the mounting plate 62. The isolator 94c may permit the mounting plate 62 to deflect axially along the longitudinal axis 20 as required to retain axial alignment of the rails 18 of adjacent modules 10a, 10b. The isolators 94c are elastomeric or otherwise deflectable to permit axial deflection of the mounting plate 62. In the illustrated embodiment, fasters 94 include isolators 94c on one lateral side of the apparatus 10. In other words, the isolators 94c are applied only to the fasteners 94 which connect mounting plate 62 to two adjacent columns 26 in the longitudinal direction (i.e., columns at a common lateral position spaced apart parallel to the longitudinal axis 20).
With continued reference to FIGS. 3A-3D, the mounting plate 62 includes four spacer holes 98 configured for attaching the downstream mounting plate 62b of the first module 10a to the upstream mounting plate 62a of the second module 10b. In the illustrated embodiment, the spacer holes 98 are also positioned in a rectangular array. In the illustrated embodiment, each of the spacer holes 98 are located at a lateral position between the rail holes 78 and the column holes 86 and at a vertical position between the common height of the rail holes 78 and the column holes 86.
As illustrated in FIG. 6, spacers 102 are configured to space the downstream mounting plate 62b of the first module 10a from the upstream mounting plate 62a of the second module 10b. In the illustrated embodiment, the spacers 102 are located between, e.g., directly between, the downstream mounting plate 62b of the first module 10a and the upstream mounting plate 62a of the second module 10b. The spacers 102 are fastened to the downstream mounting plate 62b of the first module 10a and the upstream mounting plate 62a of the second module 10b to set an axial position (or in other words, inhibit axial deflection) of the first module 10a relative to the second module 10b parallel to the longitudinal axis 20. In the illustrated embodiment, the spacers 102 define a mechanically bolted interface between the downstream mounting plate 62b of the first module 10a and the upstream mounting plate 62a of the second module 10b. In the illustrated embodiment, the spacers 102 have axial ends which are engaged by bolts 102a, 102b such that the spacers 102 act as two-sided nuts connecting the bolts 102a, 102b to form an attachment between the first module 10a and the second module 10b independent of the rails 18. The bolts 102a, 102b rest upon the inwardly facing surface 66 of the respective mounting plates 62 of the first and second modules 10a, 10b.
Finally, with reference to FIGS. 3A-3D and reference to FIG. 3, the mounting plate 62 includes four conveyor mount holes 110 configured for attaching a conveyor mount 114 to both the mounting plate 62 and the rails 18. The conveyor mount 114 is best illustrated in FIGS. 3 and 7. The conveyor mount 114 circumscribes the rails 18 (FIG. 3), and is further attached to the frame 14 through fasteners 118 which secure the conveyor mount 114 to the conveyor mount holes 110 of the mounting plate 62 (FIG. 7). The conveyor mount 114 is configured to support a conveyor 120 (FIG. 2) on the apparatus 10.
The conveyor 120 (FIG. 2) is configured to pass the cup between successive modules 10a-10c of the apparatus 10 such that the process unit 24 within each successive module 10a-10c completes a successive task on the cup. The cup may be substituted for another work piece in realms outside of cup filling and sealing. The conveyor 120 may be an intermittent conveyor capable of conveying and stopping at a process unit 24 for the process unit 24 to complete the task on the cup. The intermittent conveyor 120 may convey an index length along the longitudinal axis 20 before stopping at a process unit 24.
As best illustrated in FIG. 7, the rails 18 each have an upstream end 18a and a downstream end 18b. The upstream end 18a and the downstream end 18b each have a receiver 122 at an axial end thereof. The receiver 122 extends parallel to the longitudinal axis 20 towards the center of the rail 18 from the respective end 18a, 18b. The receivers 122 can be blind threaded holes in some constructions, as illustrated. The outboard alignment feature 126 and the inboard alignment features 130, 134 include shafts which are configured to engage the receiver 122 to secure the outboard alignment feature 126 and the inboard alignment features 130, 134 to the rails 18. The outboard alignment feature 126 and the inboard alignment features 130, 134 can be threaded shafts which engage the blind threaded holes of the receivers 122, as illustrated.
In the case of the modules 10a, 10b illustrated in FIG. 7, the upstream end 18a is received axially by the counterbored surfaces 82 of the holes 78 with the upstream end 18a abutting the counterbored surface 82 recessed from the inwardly facing surface 66 of the upstream mounting plate 62a. An outboard alignment feature 126 engages the receiver 122 of the upstream end 18a and the upstream mounting plate 62a to connect the rail 18 to the upstream mounting plate 62a, and thus, the frame 14. Similarly, the downstream end 18b is received axially by the counterbored surfaces 82 of the holes 78 with the downstream end 18b abutting the counterbored surface 82 recessed from the inwardly facing surface 66 of the downstream mounting plate 62b.
With continued reference to FIG. 7, a first inboard alignment feature 130 (i.e., a first alignment feature) is connected to the downstream end 18b of the first module 10a. The first inboard alignment feature 130 secures the downstream end 18b of the rail 18 of the first module 10a to the downstream mounting plate 62b of the first module 10a. The first inboard alignment feature 130 protrudes axially from the outwardly facing side 70 of the downstream mounting plate 62b of the first module 10a. A second inboard alignment feature 134 (i.e., a second alignment feature) is connected to the upstream end 18a of the second module 10b. The second inboard alignment feature 134 secures the upstream end 18a of the rail 18 of the second module 10b to the upstream mounting plate 62a of the second module 10b. The second inboard alignment feature 134 protrudes axially from the outwardly facing side 70 of the upstream mounting plate 62a of the first module 10a.
With reference to FIG. 7, in the assembly of the modules 10a, 10b, the rails 18 of the first module 10a and the second module 10b are aligned in coaxial pairs (e.g., four pairs), and all the rails 18 are parallel with the longitudinal axis 20—or in other words, define four parallel longitudinal axes. Axial clearance between the modules 10a, 10b is taken up until the inboard alignment features 130, 134 engage each other. Any remaining slack is taken up between the first module 10a and the second module 10b as the spacers 102 are tightened. This process is repeated for each aligned set of rails 18 between the two modules 10a, 10b. As such, the rail 18 of the first module 10a is coaxially and longitudinally secured to the rail 18 of the second module 10b with all of the rails 18 of both the first module 10a and the second module 10b being parallel to the longitudinal axis 20.
In the illustrated embodiment of FIG. 7, the first and second inboard alignment features 130, 134, are, respectively, male and female connectors. In the assembly of the apparatus 10, the first and second inboard alignment features 130, 134, as well as the outboard alignment feature 126, are coaxial (i.e., positioned along) with the longitudinal axis 20. The spacers 102 are removable from the mounting plates 62 of the first module 10a and the second module 10b such that the second module 10b is separable from the first module 10a. The first and second inboard alignment features 130, 134 extend through the rail holes 78 of the downstream mounting plate 62b of the first module 10a and of the upstream mounting plate 62a of the second module 10b, respectively.
With continued reference of FIG. 7, the male first inboard alignment feature 130 includes an outwardly projecting surface 138. As typical with female connectors, the female second inboard alignment feature 134 defines a void 142 operable to receive the outwardly projecting surface 138 of the first inboard alignment feature 130. In the illustrated embodiment, the outwardly projecting surface 138 is received within the void 142 to align the rail 18 of the second module 10b with the rail 18 of the first module 10a. When the outwardly projecting surface 138 is received within the void 142, it is said that the outwardly projecting surface 138 is secured with the void 142. Optionally, the outwardly projecting surface 138 is rounded or conical such that when the outwardly projecting surface 138 and the void 142 contact each other, the rounded or conical outwardly projecting surface 138 forces alignment of the rail 18 of the first module 10a with the rail 18 of the second module 10b. In the apparatus 10, the entirety of both outwardly projecting surface 138 and the void 142 are positioned between the downstream mounting plate 62b of the first module 10a and the upstream mounting plate 62a of the second module 10b.
With continued reference of FIG. 7, the outboard alignment feature 126, the male first inboard alignment feature 130, and the female second inboard alignment feature 134 are each made from 303 stainless steel. In other embodiments, the outboard and inboard alignment features 126, 130, 134 may be made from 304 or 316 stainless steel. In the illustrated embodiment, the male first inboard alignment feature 130 has an outer diameter of 35 mm+0/−0.1 mm. In the illustrated embodiment, the female first inboard alignment feature has an inner diameter of 35.1 mm+0.1/−0 mm. This permits the first inboard alignment feature 130 to nest within the second inboard alignment feature 134. In other embodiments, the materials, diameters, and tolerances of the first and second inboard alignment features 130, 134 may differ based on other design parameters of the apparatus 10.
As illustrated in FIG. 3, the connection between the rails 18 of second module 10b and the rails 18 of the third module 10c follows the same format as described with respect to the connection between the rails 18 of the first module 10a and the second module 10b. Both connections utilize the first and second inboard alignment features 130, 134. Successive modules 10d attached to the third module 10c also follow the same format as described with respect to the first module 10a and the second module 10b.
The apparatus 10 includes the conveyor mounted on the conveyor mount 114 and functioning in conjunction with the rails 18 to pass the cup between the process units 24 mounted within each module 10a-10c for each module to successively complete a task associated with filling the cup with a comestible and sealing the comestibles within the cup from the environment. The conveyor 120 is configured to hold, carry, and discharge various sized cups so to pass the cup between each of the process units 24 mounted within each of the modules 10a-10c. Other process units not related to cup filling and sealing may also be placed within the modules 10a-10c of the frame 14 for use with the conveyor 120.
The cup may be made of, for example, a thermoplastic such as polypropylene or polyethylene. Alternately, the cup material can be coated or uncoated paper, and the cup may be compostable. In some constructions, the cup is partially or entirely constructed from recycled materials. The cup may be filled with a comestible. The comestible can be in liquid or semi-liquid form. For example, the comestible may be orange juice, tomato juice, milk, ice cream, soft drinks, gelatin type desserts, salads, and other types of food. The cups are provided with tapered (e.g., truncated cone) walls having an enlarged upper open end having a thickened or rolled lip. The cup may be shaped in many ways. Common shapes for cups include square or rectangular cups with single or multiple cavities. The cups may be round cups that vary in diameter, height, and taper. Oval cups and cups that are joined to form multiple individual containers separated by the end user for single use are also conceived. In some instances, and especially when the cups are asymmetric, there may be a need for consistent orientation of the cup during processing in the cup filling and sealing apparatus 10. A cover (sometimes referred to as a “seal”) that closes the open end of the cup may be applied to the lip. As such, the cup is closed and sealed by the cover to prevent spilling and contamination of the comestibles or other contents within the cup. The cover can be made from, for example, foil, plastic, or an organic film, and/or a coated paper or plastic.
As previously mentioned, process units 24 may be mounted to the rails 18 for operation in each module 10a-10c of the apparatus 10. Each process unit 24 may be mounted within any of the modules 10a-10c so long as the axial length of the module 10a-10c is appropriate for the process unit 24. For example, a single process unit 24 can be mounted on the rails 18 of the module 10a, removed from the module 10a, and replaced into engagement with the rails 18 of the second module 10b. As previously mentioned, multiple process units 24 may be positioned within a single module 10a-10c. In the illustrated embodiment, each rail 18 has a common cross-section to permit usage of the rail 18 within any of the modules 10a-10c and permit interchangeable attachment of the process unit 24 onto the rails 18 within any of the modules 10a-10c. For example, the illustrated rails 18 all have a circular cross-section taken perpendicular to the longitudinal axis 20. It is also noted that the rails 18 may be of solid material (e.g., metal) cross-section with the exception of the ends 18a, 18b.
Each process unit 24 functions in conjunction with the conveyor 120 to complete a task associated with cup filling and sealing on the cup. For example, the process unit 24 within the module 10a receives the cup from the conveyor 120, and completes a first task on the cup. Then, the process unit 24 returns the cup to the conveyor 120. The cup is passed to the next module 10b by the conveyor 120 for completing the successive task, and so on. As such, each process unit 24 accomplishes at least one task of a series of tasks of the cup filling and sealing apparatus 10.
FIG. 9 illustrates an infeed process unit 24a. The infeed process unit 24a functions as a point of access on the apparatus 10 where cups are loaded into a magazine 146, and individually dispensed into a carrier plate 150 (i.e., a cup holder). A vacuum pull down station 154 may be used to assist in placing the cups into the carrier plate 150 so that it the cups are properly aligned within the carrier plate 150. As the conveyor indexes the carrier plates 150 (i.e., translates the carrier plates 150 along the longitudinal axis 20), a series of sensors 158 are used to check if there are multiple cups in a single carrier plate 150 pocket, or if a cup is missing entirely.
FIG. 10 illustrates a dosing process unit 24b. The dosing process unit 24b contains a pump apparatus 162 that doses a particular product (e.g., yogurt, cream cheese, sour cream, etc.) into the cup. A fill lift mechanism 166 may be employed within this module to assist in lifting the cups partially out of the carrier plate 150 to prevent product splashing out of the cups.
FIG. 11 illustrates a sealing process unit 24c. The sealing process unit 24c contains a cup sealing apparatus 170 configured to apply a sealing material (as described above), which may be metallic foil lids or a roll stock film, to the top of the cup. The cup sealing apparatus 170 is operable to positively seal the cup through a combination of heat and pressure, provided by a drive mechanism 174 and heater heads 178. In one embodiment of the sealing process unit 24c, the heater heads 178 are configured to float to align with a cup that is misaligned relative to the carrier plate 150.
FIG. 12 illustrates a discharge process unit 24d. The discharge process unit 24d provides for the sealed cups to be discharged from the apparatus 10 and onto other equipment, such as a stand-alone belted conveyor (not shown). A lift out station 182 is typically used to fully lift the cups out of the carrier plates 150 into a position for which the cups are able to be swept off of the lift out station 182, out of pedestals 186, and through a discharge sweep station 190 to be exited from the apparatus 10.
Returning to FIGS. 7 and 8, a portion of the magazine 146 is illustrated. The magazine 146 is supported on the rails 18 by a longitudinal alignment plate 194. In the illustrated embodiment, there are two longitudinal alignment plates 194 connecting the magazine 146 to two upper rails 18 of the first module 10a. The alignment plates 194 are loosely fitted around the rails 18 to permit longitudinal translation of the magazine 146 along the longitudinal axis 20 upon receiving a threshold force along the longitudinal axis 20, but to inhibit motion of the magazine 146 along the longitudinal axis 20 upon receiving a force lower than the threshold force along the longitudinal axis 20 (e.g., during operation of the magazine 146). Another alignment plate 198 is fastened to the upper rails 18 at a fixed position along the longitudinal axis 20. A jack screw 202 connects the alignment plate 194 to the alignment plate 198, and the jack screw 202 is operable to apply the threshold force to move the alignment plate 194 relative to the alignment plate 198. As such, the magazine 146 is movable along the rails 18 by operation of the jack screw 202. The magazine 146 may have additional adjustable features to locate the magazine 146 in an operable position aligned with the vacuum pull down station 154. As illustrated in FIG. 4, the jack screw 202 is located between the first and second lateral ends 34a, 34b of the module 10a, for example in a laterally central region or lateral center position. As such, the alignment process using the jack screw 202 can be carried out by a technician from either lateral side of the apparatus 10, not only from a single designated service side of the apparatus 10. Moreover, the alignment plates 194, 198 and the jack screw 202 may dispense with any individual alignment mechanisms that align portions separately, ensuring that the magazine 146 maintains a consistent orientation on the rails 18 during longitudinal alignment. The magazine 146 may be replaced with a component of or an entirely different functional process unit 24 such that the different functional process unit 24 is movable along the longitudinal axis 20 as described above with respect to the magazine 146.
In the illustrated embodiment of FIG. 13, the jack screw 202 is located at a lateral position between each of the rails 18 which the alignment plates 194, 198 are supported. In the illustrated embodiment, the jack screw 202 is located at a lateral position equally spaced from each of the rails 18 (i.e., a lateral midpoint of the alignment plates 194, 198). As illustrated in FIG. 4, the jack screw 202 is located equidistant from the first and second lateral ends 34a, 34b of the module 10a. This allows a user to operate the jack screw 202 at either lateral side of the apparatus 10. The jack screw 202 is aligned parallel with the longitudinal axis 20 such that operation of the jack screw 202 above the threshold force translates the magazine 146 along the longitudinal axis 20. In the illustrated embodiment, the magazine 146 may has additional adjustable features to locate the magazine 146 in an operable position (e.g., along the lateral axis 21 or the vertical axis 22) for use with the vacuum pull down station 154.
With continued reference to FIG. 13, each alignment plate 194, 198 includes a first lateral end 194a, 198a, and a second lateral end 194b, 198b. Each lateral end 194a, 198a, 194b, 198b includes a top portion 194c, 198c, and a bottom portion 194d, 198d. In the illustrated embodiment, each top portion 194c, 198c and bottom portion 194d, 198d are connected by a central portion 194e, 198e, which spans between the first lateral end 194a, 198a and the second lateral end 194b, 198b. The central portions 194e, 198e each include a jack screw hole 194h, 198h operable to receive the jack screw 202.
Further, as best shown in FIG. 18, each top portion 194c, 198c and bottom portion 194d, 198d are separable from each other at a parting line 194f, 198f defining a rail hole 194g, 198g with the top portion 194c, 198c and the bottom portion 194d, 198d. The top portions 194c, 198c and bottom portions 194d, 198d are connected to each other by fasteners 206. The fasteners 206 extend through the first and second lateral ends 194a, 198a, 194b, 198b such that each alignment plate 194, 198 surrounds the rail 18. In the illustrated embodiment, the fasteners 206 extend parallel to the vertical axis 22. As such, when the fasteners 206 connect the top portions 194c, 198c, to the bottom portions 194d, 198d while surrounding the rails 18, each alignment plate 194, 198 and thus the magazine 146 is supported on the rails 18.
With continued reference to FIG. 13, a bushing 210 is located between each alignment plate 194 and the rail 18. More specifically, each alignment plate 194 has a bushing 210 located at each lateral end 194a, 194b between the top portion 194c and the bottom portion 194d and the rail 18. The bushing 210 inhibits motion of the magazine 146 along the longitudinal axis 20 upon receiving a force lower than the threshold force along the longitudinal axis 20 (e.g., during operation of the magazine 146). As such, the alignment plate 194 loosely supports the magazine 146 upon the rails 18. The bushing 210 is sized to engage the rail holes 194g of the alignment plate 194. The rail hole 198g of the alignment plate 198 may be sized to contact the rail 18 directly such that the alignment plate 198 is fixed to the rail 18 in a direction parallel to the longitudinal axis 20.
FIGS. 19 and 20 illustrate the connection between the alignment plates 194, 198 with the jack screw 202 in detail. A sleeve nut 214 is provided between the jack screw 202 and the alignment plate 194, the sleeve nut 214 engaging the jack screw 202. In the illustrated embodiment, the sleeve nut 214 and the jack screw 202 are threaded, with the threads of the sleeve nut 214 engaging threads of the jack screw 202. The sleeve nut 214 is positioned radially outwardly of the jack screw 202 to engage the jack screw hole 194h of the alignment plate 194. In the illustrated embodiment, the sleeve nut 214 includes sleeve nut retainers 214a positioned on either longitudinal side (i.e., along the longitudinal axis 20) of the alignment plate 194 configured to optionally seal the sleeve nut 214 at the same longitudinal position relative to the alignment plate 198 (i.e., along the longitudinal axis 20) as the alignment plate 194. Further, the sleeve nut retainers 214a are responsible for preventing the sleeve nut 214 from spinning inside the alignment plate 194. The sleeve nut retainers 214a project radially outwardly from the sleeve nut 214 such that the sleeve nut retainers 214a longitudinally abut either side of the alignment plate 194. When the jack screw 202 is rotated to apply at least a threshold force (i.e., static friction between the bushing 210 and the rail 18), the jack screw 202 applies a torque to the sleeve nut 214. The torque applied from the jack screw 202 to the sleeve nut 214 results in a longitudinal force along the longitudinal axis 20 applied to the sleeve nut 214. As a result of the longitudinal force, the sleeve nut 214 is translated along the longitudinal axis 20, causing translational motion of the alignment plate 194 and thus the magazine 146 along the longitudinal axis 20 relative to the alignment plate 198. A bolt 218 engages the jack screw 202 adjacent the sleeve nut 214. The bolt 218 prevents the jack screw 202 from being disengaged (i.e., having the threads of the jack screw 202 be removed) from the sleeve nut 214. A washer 222 is positioned longitudinally between the head of the bolt 218 and the jack screw 202.
At the opposite end of the jack screw 202, flanged guide bushings 226a, 226b are located within and locate the jack screw 202 within the jack screw hole 198h of the alignment plate 198. The flanged guide bushiness 226a, 226b align the jack screw 202 parallel with the longitudinal axis 20. The flanged guide bushings 226a, 226b include heads which protrude radially outwardly from jack screw hole 198h on either longitudinal side of the alignment plate 198. A bolt 230 engages the jack screw 202 adjacent the flanged guide bushings 226a, 226b. A washer 234 is positioned longitudinally between the head of the bolt 230 and the jack screw 202.
In the cup filling and sealing apparatus 10, the jack screw 202 is used to translate the magazine 146 between a first desired longitudinal position relative to the alignment plate 198 and a second desired longitudinal position displaced from the first desired longitudinal position. As such, the magazine 146 is movable along the rails 18 without disassembling the cup filling and sealing apparatus 10 and reassembling the magazine 146 onto the rails 18. As the magazine 146 is shifted along the rails 18 with the jack screw 202, a distance between the magazine 146 (or another process unit 24) and the other process units 24 of the cup filling and sealing apparatus 10 is adjusted. The conveyor can then be operated such that successive process units 24 can perform a function (e.g., infeed, dosing, sealing, discharge, etc.) to the cup without the respective process unit 24 being longitudinally (e.g., along the longitudinal axis 20) misaligned from a desired position along the cup filling and sealing apparatus 10 corresponding with the index length of the conveyor.
Optionally, the conveyor may include an end (not shown) which is connected to the alignment plate 194. As such, upon rotation of the jack screw 202, the tension of a belt (not shown) of the conveyor which passes between ends of the conveyor is adjusted. Alternatively, the alignment plate 194 may be separate from the magazine 146 so to adjust the tension in the belt of the conveyor independent of the magazine 146. The jack screw 202 may engage another component of any of the process units 24 other than the magazine 146.
The embodiment(s) described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present disclosure. As such, it will be appreciated that variations and modifications to the elements and their configuration and/or arrangement exist within the spirit and scope of one or more independent aspects as described.
Various features of the invention are set forth in the following claims.
Patent Grant
11511900
