Patent Grant
7114535
The present invention relates to an apparatus and method for filling containers, such as bottles and the like, with a liquid by conveying the containers through a filling machine.
Automated filling machines configured for filling any manner of container processed through the machine by a conveyor or the like are old and well known in the art. For example, a conventional high-speed filling machine typically uses a worm gear or screw-like device to receive containers (i.e., bottles) conveyed in single file and in contact with each other. The worm gear engages each container and spaces the containers apart a desired distance corresponding to the spacing of downstream filling valves. The containers are typically conveyed from the worm gear to a rotating star wheel that receives the containers in individual pockets or recesses. The star wheel may further convey the bottles to one or more additional star wheels, to a rotating table or platform of the filling machine, or may directly convey the bottles under the heads of the rotary filling machine. Examples of such filling machines are described, for example, in the following U.S. Pat. Nos. 2,666,564; 3,519,108; 4,053,003; 4,588,001; 6,253,809 B1; and 6,474,368 B2.
With the device according to U.S. Pat. No. 4,567,919, the containers are spaced apart on a conveyor by a pair of parallel screws and conveyed on the same conveyer directly to the filling valves of the rotary filler without the use of a star wheel.
U.S. Pat. No. 5,029,695 describes a star wheel having a plurality of circumferentially spaced orienting devices around its periphery. Each of the orienting devices includes moveable fingers which can readily assume the contour of different containers. However, the containers must still be indexed prior to being conveyed to the star wheel.
Conventional rotary filling machines of the type described above used in modern high-speed processing lines require relatively sophisticated drives, gearing, and control systems for ensuring precise coordinated movement between the different in-feed and out-feed star wheels, worm gears, and so forth. Also, the star wheel assemblies take up valuable floor space. A typical star wheel may be, for example, 4 feet in diameter. The star wheels also require maintenance and upkeep, and generally add to the overall cost of the filling operation.
Conventional rotary filling operations also generally process the containers in a single file or row through the filling machine, primarily due to the indexing functions of the worm gears and/or star wheels. To accomplish multiple parallel row filling operations with conventional star wheel indexing technology would require complicated and expensive gearing and drive arrangements and is not considered commercially viable. Multiple row filling is thus often provided by linear-type filling machines as described, for example, in U.S. Pat. No. 5,878,796. In this linear design, the containers are typically conveyed serially as a group into the filling machine and captured or indexed into position under filling nozzles or orifices. The containers are typically held fixed and motionless while they are filled. Once the containers are filled, the indexing mechanism releases the containers and the filled containers are conveyed out on the same conveyor and another grouping of containers in indexed into position for filling. The linear-type machines, however, also have drawbacks, particularly with respect to processing speed. The basic architecture of the rotary system design is clearly superior with respect to potential through-put of containers as compared to the linear systems. Also, the rotary systems make far more efficient use of floor space.
Objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
The present invention relates to improvements in a rotary filling machine that allow for a relatively simple yet efficient method for indexing containers conveyed to the machine while greatly simplifying the mechanical components needed to carry out the indexing function. The machine overall is greatly simplified without sacrificing speed or efficiency. Additionally, multiple rows of containers may be simultaneously processed through the rotary filling machine without adding to the complexity of the machine, resulting in significantly increased through-put numbers.
In accordance with the invention, a continuous circular motion filling machine is provided for filling containers conveyed thereto. The invention is not limited to any particular type of filling material, and may be used for filling containers with any type of flowable material or substance, such as liquids, powders, granular products, etc. In one particular embodiment, the machine includes a rotating platform having an in-feed section that is disposed to receive empty containers and an out-feed section disposed to transfer filled containers from the rotating platform. The platform rotates relative to a vertical rotating axis. In a particular embodiment, the rotating platform is a generally circular rotating member that receives the containers at the in-feed section from a separate in-feed conveyor, and transfers the containers at the out-feed section to a separate out-feed container. In an alternative embodiment, the rotating platform, in-feed conveyor, and out-feed conveyor may be defined by a continuous conveyor wherein the rotating platform section of the continuous conveyor is defined by a semi-circular portion of the continuous conveyor.
A filling turret is disposed generally above the rotating platform and rotates at a speed corresponding generally to that of the rotating platform. The filling turret includes a plurality of circumferentially disposed filling elements that are movable between a rest position and a filling position as the turret rotates between the in-feed and out-feed sections.
In a particular embodiment of the invention, the filling turret includes a plurality of circumferentially disposed filling heads. The filling heads are disposed generally above the rotating platform and rotate at a speed corresponding to the rotational speed of the platform. Each filling head comprises a grouping of the filling elements arranged in a pattern corresponding to a pattern of containers indexed in groups on the rotating platform. For example, in on particular embodiment, the turret may include eight filling heads, with each filling head having, for example, twenty-two filling elements. The filling elements associated with a particular respective filling head are controlled and operated generally simultaneously, as described in greater detail herein.
In a particular embodiment, a plurality of radially extensible and retractable indexing arms are circumferentially spaced around the rotating platform. At the in-feed section, the indexing arms are at a retracted position and are subsequently extended as the rotating platform rotates so as to index the containers into groups on the rotating platform. The groups are defined between the indexing arms and consist of at least one container. For example, a group may consist of a plurality of containers arranged in a single serial row between adjacent indexing arms. In an alternative embodiment, a group may consist of a plurality of containers arranged in multiple parallel rows between adjacent indexing arms. In still a different embodiment, a group may consist of a single container located between adjacent indexing arms. Each group of containers, regardless of its number of containers, is arranged between the indexing arms in a desired pattern and spacing that corresponds to the pattern and spacing of the filling heads on the rotating turret. In this manner, the filling heads are movable as the turret rotates from a rest position to a filling position subsequent to indexing of the containers on the platform for a filling operation.
In an alternative embodiment, the containers may be of a size and shape such that they may be conveyed on the rotating platform in continuous contact without the use of indexing arms. This may be the case, for example, where the containers are relatively large and the filling elements are circumferentially spaced to accommodate the size of the containers such that the space between filling elements within a filling head is the same as the space between adjacent filling elements of different filling heads.
In a particular embodiment, in-feed guide elements are disposed generally at the in-feed section so as to guide containers from an in-feed conveyor onto the rotating platform in a desired pattern. For example, the containers may be guided by the in-feed guide elements onto the rotating platform in a single serial row. In an alternative embodiment, the containers may be guided onto the rotating platform by the in-feed guide elements in multiple parallel rows. The in-feed guide elements extend around at least a portion of the circumference of the rotating platform beyond the circumferential location where the filling heads (or filling elements) are movable from their rest position to their filling position. In this way, the filling heads essentially capture the containers prior to the containers leaving the guide elements and prevent the containers from sliding or otherwise being propelled from the rotating platform. It is thus not necessary to provide guide or rail elements around the circumference of the rotating platform.
It may also be desired to include exit guide elements disposed generally at the exit section of the rotating platform. The exit guide elements are disposed so as to convey the filled containers from the rotating platform onto an out-feed conveyor. The filling heads are movable from their filling position (wherein they essentially capture the containers) to their rest position after the containers are moved into the exit guide elements. Again, this serves the purpose of ensuring that the containers are at all times securely conveyed and cannot tip over or slide off of the platform.
If used, the indexing arms may be controlled to automatically move to their retracted position at the in-feed and out-feed sections of the rotating platform so that the containers are conveyed onto the platform in a generally continuous contacting sequence. After the containers have been transferred onto the rotating platform, the indexing arms are subsequently automatically extended from their retracted position so as to index the containers into a predetermined pattern or grouping between the indexing arms. A particularly effective and simple mechanism for controlling the automatic functions of the indexing arms is by way of a cam actuated system wherein the arms include a cam follower that travels along a cam race surface, the race surface having a particular configuration so as to withdraw or retract the indexing arms at the in-feed and out-feed sections, and to extend the arms for indexing the containers as described above. It should be appreciated, however, that alternative methods are available for controlling the indexing arms, including mechanical drive systems, spring systems, etc. All such control systems are within the scope and spirit of the invention.
The filling heads are movable between their rest and filling positions as the filling heads rotate with the filling turret. In a particular embodiment, the filling heads are movable in a vertical direction. The heads are at their rest position generally at the in-feed and out-feed sections of the rotating platform so that empty containers can be conveyed onto the platform at the in-feed section, and filled containers can be transferred off of the platform at the out-feed section. In a particular embodiment, the filling heads may be movably supported on generally vertically oriented support arms or members that are circumferentially spaced around the filling turret. The filling heads may be driven in reciprocating vertical paths on the support arms by any suitable drive mechanism. For example, in one particularly suitable arrangement, the filling heads are driven on the support arms by a cam drive system wherein the filling heads include cam followers engaged within a stationary cam track. The track has a configuration such that, as the filling turret rotates, the cam followers cause the filling heads to be moved vertically on their respective support arms.
As mentioned, after the containers have been indexed on the rotating platform, the filling head is moved from its rest position to a filling position wherein individual filling elements of the filling head engage with individual respective containers. At this point, a filling operation may be commenced, as described in greater detail below. Once the filling operation is completed, the containers can be directed from the rotating platform. In this regard, it should be understood that the filling operation may be completed within a relatively short rotational arc of the rotating platform, and that the out-feed section may be defined at this location. For example, the out-feed section may be defined at an arc position of 90 degrees, 180 degrees, 270 degrees, and so forth. In a desirable embodiment, the out-feed section is defined generally adjacent the in-feed section so that the containers are conveyed from the rotating platform in a direction generally parallel to but opposite their in-feed direction.
It may be desired to maintain the filling heads in their filling position until the containers are conveyed from the rotating platform, or at least conveyed into exit guide elements, even if the filling operation is completed before the out-feed section. As mentioned above, this arrangement serves to ensure that the containers are positively guided and captured as they are conveyed on the rotating platform.
The filling heads are individually supplied with a filling material, such as a liquid, slurry, powder, etc., from a central location. For example, a reservoir may be disposed generally atop of the rotating turret, with the filling heads comprising accumulator tanks supplied with a liquid from the reservoir by way of a flexible coupling. The flexible coupling allows the filling heads to move vertically with respect to the reservoir. It should be appreciated that various arrangements of tanks, reservoirs, and the like may be utilized in this regard.
The filling elements associated with each filling head are in fluid communication with the accumulator tank and include valve elements having an open position for dispensing liquid into the containers, and a closed position for preventing the dispensing of liquid after the containers are filled. An advantageous feature of the system according to the invention relates to the fact that multiple filling elements are simultaneously operated and controlled by a single filling head. For example, each filling head may comprise a central control member, such as a supply/electrical manifold assembly, wherein the control member is supplied with any combination of electrical or pneumatic lines for the actuation and control of the individual filling elements. For example, depending on the type of liquid or beverage being filled, each filling element may require a number of pneumatic lines for a filling sequence, such as a vent line, a purge line, a pressurized air line, and so forth. The invention is not limited by the type of filling head or filling requirements of each head. The filling element requirements would be supplied to the filling head central control member, and the filling elements would in turn be connected to the control member. For example, multiple pneumatic lines may be connected to the control member (i.e. a manifold mounted externally or internally of the filling head). The individual filling elements would then be connected directly to the manifold such that all of the filling elements are supplied from the manifold and operated generally simultaneously in a filling sequence. In a particular embodiment, the filling elements may be supplied from the manifold by a common header such that only a single connection line is needed from the manifold to the filling elements. In an alternate embodiment, each of the filling elements may be individually connected to the control member manifold. Any manner of conventional quick disconnects, connectors, and so forth may be used in this regard.
As mentioned, the groups of containers may be conveyed in direct contact against each other between the indexing arms. In this embodiment, the indexing arms have a width and circumferential spacing to ensure that the individual containers within a group are generally aligned with the filling elements of a respective filling head. The indexing arms may comprise a shaped tip at their radial end having an angled surface at a following (upstream) side of the arm in a direction of rotation of the rotating platform. In this manner, upon extension of the indexing arms from their retracted position, line pressure of the containers is relieved to the following side of the arms, generally upstream to the in-feed conveyor.
In an alternate embodiment, the indexing arms are variably positionable in a radial direction and include an angled or curved leading edge surface. The spacing of containers between the indexing arms can be varied by adjusting the degree of radial extension of the indexing arms. In this manner, containers of different size may be processed without changing the filling heads or filling elements within the heads. For example, in one embodiment, in-feed guide elements are disposed at the in-feed section of the platform so as to guide the containers onto the rotating platform in a single serial row. The indexing arms are of a number and spacing so as to be extendable between each of the containers. In other words, only a single container is indexed between adjacent arms. The radially extended position of the arms will dictate the circumferential spacing of the containers. The machine may thus be easily converted for containers of a different size merely by adjusting the extension position of the arms such that the containers are contacted along a different location of the angled surface of the arms. This feature may add significantly to the versatility of the filling machine.
The present invention also includes various embodiments of methods for filling containers with a liquid in an automated filling operation. The methods incorporate many of the operational characteristics described above. For example, in a particular embodiment, the method entails conveying a generally continuous stream of adjacent contacting containers to an in-feed section of a circular filling machine. At the in-feed section, the continuous stream of containers are transferred onto a generally circular rotating path. After the transferring step, the continuous stream of containers may be indexed while they rotate on the rotating path into groups having a desired number of containers in each group. Alternatively, the containers may be transferred and conveyed along the circular rotating path without indexing. Subsequently, the groups of containers are engaged with respective rotating filling heads, the filling heads having filling elements that engage with the individual containers within the groups. The containers are then filled by way of the filling heads as they are conveyed along an arcuate portion of the circular rotating path.
Various other method embodiments according to the invention include operational principals of the filling machine as described herein.
Embodiments of the invention will be described in greater detail below by reference to the appended figures.
Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the figures. Each embodiment is presented for purposes of explaining the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to yield still a different embodiment. It is intended that the invention include these and other modifications and variations as come within the scope and spirit of the invention.
Referring to
The machine 10 includes a rotating platform, generally 18 having an in-feed section 20 and an out-feed section 22. At the in-feed section 20, containers 12 are transferred from an in-feed conveyor 14 onto the rotating platform 18. Similarly, at the out-feed section 22, filled containers 12 are transferred from the rotating platform 18 onto an out-feed conveyor 16. The in-feed and out-feed conveyors 14, 16, may comprise any configuration of conventional conveyor, and are illustrated in the drawings as conventional link conveyors.
In the illustrated embodiments, the rotating platform 18 is a generally circular rotating plate member, as particularly illustrated in
A filling turret 24 is disposed generally above the rotating platform 18 and rotates relative to the vertical axis 26 at a rotational speed that corresponds generally to that of the rotating platform 18. In this regard, the rotating turret 24 and platform 18 may be driven by a common drive mechanism, as described in greater detail below.
The filling turret 24 includes a plurality of radially disposed filling elements, generally 30, that are movable from a rest position relative to the containers 12 to a filling position wherein the filling elements 30 engage with the containers 12 for a filling operation. In a particular embodiment, the filling elements 30 may be individually supplied and controlled. In the illustrated embodiments, the filling elements 30 are configured in groups with respective filling heads 28. Each filling head 28 includes an accumulator tank 60 in which a grouping of individual filling heads 30 are configured. Each accumulator tank 60 is in turn in communication with a central reservoir 32 by way of, for example, flexible coupling hoses 34. Referring to
Referring particularly to
Referring to
Each of the block members 58 includes at least one cam follower 56 that moves along a cam track 54 defined in a stationary cam track member 50. Referring particularly to
In the illustrated embodiment, the cam track members 50a and 50b are stationarily supported relative to a fixed vertical support member 48 by way of, for example, radial support arms 52 illustrated diagrammatically in
It should also be appreciated that the cam actuation system described herein for automatically driving the filling heads 28 in their reciprocating vertical path as they rotate is but one of any manner of suitable drive mechanism. For example, the heads 28 may be motor driven by a common motor, individual motors, and so forth in alternate embodiments. The invention is not limited by any particular drive mechanism for the movable filling heads 28 so long as the drive mechanism operates to automatically move the filling heads 28 in a timed sequence as described herein.
It is important that the containers 12 are conveyed on the rotating platform 18 in a desired grouping corresponding to the number and pattern configuration of the filling elements 30. Depending on the size and shape of the containers, this may be accomplished merely by conveying the containers in serial contact with each other on the rotating platform 18 without otherwise physically indexing the containers. The individual filling elements 30 would have a uniform circumferential spacing corresponding to the spacing between the container openings. Thus, if the filling elements 30 were configured in groups in respective filling heads 28, the spacing between adjacent filling elements 30 of different heads 28 would be the same as the spacing between filling elements 30 within a filling head 28.
In an alternate embodiment illustrated in the figures wherein a plurality of the filling elements 30 are associated in a pattern with a respective filling head 28, the containers 12 are be indexed into a corresponding pattern so that when the filling heads 28 move from their rest position (position of element 28c in
Referring to the cited figures, a plurality of radially oriented indexing arms 36 are circumferentially spaced around the platform 18. Each arm 36 is movable between a retracted position and an extended position. The arms 36 are automatically retracted at the in-feed and out-feed sections 20, 22, as indicated by the arms 36a and 36b in
Each indexing arm 36 is mounted relative to the rotating platform member 18 so as to rotate therewith. In a relatively simple arrangement as indicated in
Referring particularly to
Referring to
Referring to
Referring to
Once the containers 12 have been indexed by the indexing arms 36 into groups having a number and pattern of containers 12 corresponding to the number and pattern of filling elements 30 of each respective filling head 28, the filling heads move to the filling position as indicated by the head 28d in
Referring to
Referring to
Various embodiments and arrangements of filling heads or valves used in circular or linear filling machines are well known to those skilled in the art, and any one or combination of such conventional valves may be utilized in the present invention. Such valves are available from several commercial sources such as US Bottlers Company, Inc. of Charlotte, N.C. In a particular embodiment suited for non-carbonated beverages, such as water, fruit and vegetable juices, etc., valve 70 may be a relatively simple spring actuated device wherein lowering of the elements 30 causes the alignment cap 72 to engage with the containers 12 as described above and also to move a sealing member within the valve element 70 away from a valve seat to open access 71 such that fluid within the tank 60 may then flow through the passage 73 and into the container 12. An air vent would also be included in the valve 70 for venting and relieving air from the containers 12 during the filling operation.
In other embodiments, the filling elements 30 may require any number of different sources or mediums to carry out a filling operation, particularly in the case of carbonated beverages. For example, each filling element 30 may require one or a number of pneumatic lines, including pressurized air lines, purge lines, a vent line, and so forth. Such sources and lines are indicated schematically in
In an advantageous configuration illustrated in the figures, the plurality of filling elements 30 within a respective filling head 28 are supplied with any needed lines 76 (i.e. electrical line, pneumatic line, etc.) by way of a common supply header 74 such that all of the filling elements 30 are supplied essentially simultaneously via the header 74. The header 74 is, in turn, connected to a central control member or module 78. A single such module 78 may be provided for each filling head 28, as depicted in
In a particular embodiment, each of the modules 78 may include one or more solenoid valves that are actuated in any desired timed sequence based on the rotational position of the respective filling head 28 to commence the filling operation by directing any combination of operational medium to the valves 70 via the header 74. The solenoid valves may be supplied with electrical control signals via the lines 81. The master module 80 may, in turn, be in communication with a central machine processor or control system for initiating the sequence of the solenoid valves. It should be appreciated by those skilled in the art that a vast array of configurations may be utilized to control the operational sequence of the filling elements, and that the present invention is not limited to any particular control configuration.
A particularly advantageous feature of the present invention is that a plurality of filling elements 30 within a respective filling head 28 may be controlled via a single module 78 and header 74, thus greatly simplifying the pneumatic/electrical connections and control systems. The individual filling elements 30 within a respective filling head 28 are not operated sequentially, and thus do not need individual control systems or modules. This greatly simplifies construction and operation of the machine.
As described, the platform 18 and components of the filling turret 24 are rotated at corresponding speeds such that there is virtually no relative movement between the filling elements 30 and containers 12 as the platform 18 and filling heads 28 are driven in their circular path. Any number of drive systems, gearing arrangements, etc., may be utilized for rotationally driving the respective components. In a relatively simple embodiment illustrated in
As mentioned, any number and pattern of containers 12 may be indexed between respective arms 36. It may be desired for certain types of containers that only a single container 12 be indexed between respective arms 36, as illustrated diagrammatically in
In an embodiment wherein a single serial row of containers is conveyed and filled, as illustrated in
As mentioned, the present invention also includes various embodiments of methods for filling containers with a liquid in an automated filling operation according to the operational principles discussed herein.
It should be appreciated by those skilled in the art that various modifications and variations may be made to the embodiments described herein without departing from the scope and spirit of the invention as set forth in the appended claims and their equivalents. It is intended that the invention include such modifications and variations.
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