This application is the national stage under 35 USC 371 of PCT/EP2014/000108, filed on Jan. 16, 2014, which claims the benefit of the Feb. 25, 2013 priority dates of German applications 102013101813.0 and 102013101812.2 the contents of which are herein incorporated by reference.
The invention relates to container processing, and in particular, to filling containers with liquid.
It is known to have a filling system that has a plurality of filling points. Each filling point has a filling element and a container holder. The container-holder holds the container so that it is sealed against the filling element during filling. These systems implement many different filling methods, such as open jet filling, vacuum filling, and pressurized filling. It is also known to provide controlled gas paths in the filling elements or in their filling element housings
In pressurized filling, a lifter device lifts the container holder so that it seals against the filling element. This lifting occurs during a filling phase in which the liquid filling material flows into the container. It also occurs in at least one process phase preceding this filling phase, for example when applying pressure to the container's interior.
In one aspect, the invention features an apparatus for filling bottles with liquid filling-material. Such an apparatus includes a filling system having filling point pairs, each of which includes a first filling point, a second filling point, a control module, a second gas path, and a gas path control valve. Each of the first and second filling points includes a filling element and a container holder. Each filling element has a filling element housing, a liquid channel, a delivery opening, a liquid valve, a first gas path, and a lifter device. The delivery opening delivers the liquid filling-material into a container. The liquid valve controls the delivery of the liquid filling-material. The gas path control valve provides control over the second gas path. The second gas path at least in part provides control over the filling process. The lifter device is configured for lifting and lowering the container holder. The second gas path and the gas path control valve are configured in the control module. The control module is common to both filling elements. The first gas path is connected to the control module.
Some embodiments include a third gas path. In these embodiments, the lifter device includes a pneumatically operated actuating element connected by the third gas path to a container's interior.
In another aspect, the invention features an apparatus for processing bottles. Such an apparatus includes a filling system for filling bottles with liquid filling-material. The filling system includes filling point pairs, of which one is a first filling point pair that has first and second filling points. Each of the filling point includes a filling element and a container holder. Each filling element, in turn, includes a filling element housing, a liquid channel, a delivery opening, a liquid valve, a gas path control valve, a lifter device, and a pneumatically operated actuating element. The delivery opening delivers liquid filling material to a bottle in a manner controlled by the liquid valve. The gas path control valve, meanwhile, controls the filling process. The lifting device, which includes the pneumatically operated actuating element, lifts and lowers the container holder. In operation, the pneumatically operated actuating element is connected to a bottle's interior. In this embodiment, the container holder includes a common container holder and the lifter device that together lift containers for both filling points of the filling point pair.
Among these embodiments are those including a control module, an outer gas path configured in the control module, outside of the filling elements, and common to the two filling elements of the filling point pair, and an inner gas path internal to the filling points. The gas path control valve controls the outer gas path. Among these embodiments are those in which the control module serves more than one filling point pair, and those in which it servers no more than one filling point pair. Also among these embodiments are those in which the gas path control valve is a constituent of the control module, and those in which the pneumatically operated actuating element is a constituent of the control module.
Yet other embodiments include a first structure that is common to all filling point pairs of the filling system, and a second structure. The outer gas path is configured in the first structure, which is either a plate or a ring. The second structure is either the pneumatically operated actuating element or the lifter device.
Among these embodiments are those that have a third structure. In these embodiments, the first structure has an upper side attached to the third structure, and an underside that is attached to filling elements by top sides thereof, the top side being the side that faces away from the delivery opening of the filling element. The third structure is either the gas path control valve or the pneumatically operated actuating element.
Other embodiments include a container-gas path, and a linkage. In these embodiments, the filling point pair includes first and second pneumatically operated actuating elements, and first and second filling elements associated with corresponding ones of the pneumatically operated actuating elements. During a filling process, a bottle is sealed against the first filling element, and the container gas path connects an interior of the bottle to the first pneumatically operated actuating element. As a result, the pneumatically operated actuating elements are coupled to the container holder via the linkage.
Other embodiments include a container gas path, and a linkage. In these embodiments, the lifter device includes at most one pneumatically operated actuating element. During a filling operation, the container gas path connects an inner chamber of a container that is held sealed against the filling element with the at most one pneumatically operated actuating element. During the filling operation, the at most one pneumatically operated actuating element is charged with an internal pressure of the container, and wherein the linkage couples the at most one pneumatically operated actuating element to the common container holder.
Other embodiments include those in which the pneumatically operated actuating element includes a piston/cylinder arrangement, and those in which it includes a bellows.
In other embodiments, the filling system further includes a control module and a rotor element. The rotor element separates an aseptic space below the rotor element from an atmosphere above the rotor element. Each filling element, which is disposed on the rotor, includes an upper portion above the rotor and a lower portion below the rotor. In either case, both it and the gas path control valve are disposed above the rotor element.
In other embodiments, the filling system includes control modules, with each filling point pair being associated with a separate control module.
In yet other embodiments, the filling points comprise a first filling point pair having first and second filing elements, with the first filling point pair including a first inner gas path, a second inner gas path, an outer gas path, and a seal. The outer gas path is connected to the first and second inner gas path. The first inner gas path is associated with the first filling element and the second inner gas path is associated with the second element. The seal has an opening cross-section that is greater either one of the cross section of the inner or outer gas path in a region of the seal.
In yet other embodiments, a filling point pair is adjustable such that when the filling point pair is mounted to a first rotor having a first pitch circle having a first pitch circle radius, a distance between the filling elements is equal to a first value, and, when the filling point pair is mounted to a second rotor having a second pitch circle having a second pitch circle radius that is different from the first pitch circle radius, a distance between the filling elements is equal to the first value.
In yet another aspect, the invention includes a filling system for filling bottles with liquid filling-material. Such a filling system includes filling point pairs, each having filling points. Each filling point has a filling element and a container holder. Each filling element includes a filling element housing, a liquid channel, a delivery opening that delivers liquid filling material to a bottle, a liquid valve that controls delivery through the delivery opening, a gas path control valve, and a lifter device for lifting and lowering the container holder. The lifter device includes a pneumatically operated actuating element. In operation, the actuating element connects to a bottle's interior.
In the inventive filling system, the filling points do not just constitute filling point pairs having gas path control valves in gas paths bearing process gas and/or vacuum that (gas path control valves) are common to the filling elements of each filling point pair, and/or having pneumatic actuating elements for the container holders that are common to the filling elements of each filling point pair. The gas path control valve that is common to the two filling points of each filling point pair and/or the pneumatic actuating element that is common to the two filling points of each filling point pair also form part of a single control and/or actuating module or of a multiple control and/or actuating module that has an outer controlled gas path for each filling point pair and that is connected to an inner gas path configured in each filling element of the filling point pair concerned. These inner gas paths of the filling elements are not controlled, i.e. the filling elements themselves do not possess any gas path control valves.
This modular layout offers considerable benefits. For example, it can permit the necessary connection between the filling points and a ring channel that is common to all of the filling elements of a filling system to be operated on shortened gas paths. The ring channel is used, for example, to supply and/or evacuate process gases or a vacuum. The modular layout also allows the control and/or actuating modules, and in particular the gas path control valves and/or the actuating elements, to be arranged outside a hygienic or aseptic region or space in which the filling elements, with only a partial length having the delivery opening, and the container holders, are disposed.
In a preferred embodiment of the invention, the exterior gas paths are brought together into a ring that is disposed on the same axis as the vertical machine axis of a filling machine that forms the filling system. The filling elements are preferably attached to the underside of this ring by the tops of their filling element housings.
The modular layout also makes it possible to realize different filling element sizes or spacings between filling elements, i.e. a different number of filling point pairs on rotors, each with the same filling elements and the same gas path control valves and/or pneumatic actuating elements. Adjustment to the respective filling-element spacing is then effected solely by way of a ring arranged on the same axis as the machine axis of a filling machine that has the filling system and in which the outer gas paths are configured.
In any event however, the filling elements and the multiple control and/or actuating module or single control and/or actuating module are configured such that the connection between the inner and outer gas channels is also made at the same time as the mechanical attachment of the filling elements.
As used herein, “pressure-filling” is to be understood generally to mean a filling method in which the container to be filled lies in a sealed position against the filling element. Usually before the actual filling phase, i.e. before the liquid valve is opened, the filling element is pre-tensioned, through a controlled gas path configured in the filling element, with a pressurized pre-tensioning gas (inert gas or CO2 gas) that the filling material entering the container during filling increasingly displaces as a return gas out of the container interior, again through a controlled gas path configured in the filling element. This pre-tensioning phase may be preceded by other treatment phases, for example by an evacuation and/or a purging of the container interior with an inert gas such as CO2 etc., here again through the gas paths configured in the filling element.
As used herein, “open jet filling” refers to a method in which the liquid filling material flows to the container to be filled in an open filling jet, with the container not lying with its container mouth or container opening directly against the filling element but being spaced apart from the filling element or from the latter's filling material outlet. Another feature of this method is that the air displaced by the liquid filling material from the container during the filling process does not enter the filling element or a gas-bearing region or channel therein configured, but instead flows freely into the atmosphere.
As used herein, expressions such as “essentially,” “in essence,” or “around” mean variations from an exact value by ±10%, preferably by ±5% and/or variations that are insignificant for the function.
As used herein, a “control module” includes a control and/or actuation module that carries out control, actuation, or control and actuation.
Further embodiments, advantages, and possible applications of the invention arise out of the following description of embodiments and out of the figures. All of the described and/or pictorially represented attributes, whether alone or in any desired combination, are fundamentally the subject matter of the invention independently of their synopsis in the claims or a retroactive application thereof. The content of the claims is also made an integral part of the description.
The invention is explained in detail below through the use of embodiment examples with reference to the figures. Figures:
The first and second filling points 4.1, 4.2 are formed in such a way that, in the direction of rotation A of the rotor 3, every second filling point 4.2 is adjacent to and between two first filling points 4.1. Empty bottles 2 arrive at the filling machine 1 through a container inlet 5 and leave as filled bottles 2 through a container outlet 6.
The filling points 4.1, 4.2 are configured for different filling methods. One method is pressurized filling of bottles 2. Pressurized bottle filling includes pre-tensioning a bottle's interior with a pressurized process gas or inert gas, such as CO2 gas. It can also include purging the bottle's interior one or more times with a process gas or an inert gas. Pressurized bottle filling can also include evacuating the bottle's interior, rapid or slow filling of the bottle, and pressure-relief of the bottle's interior after filling. These process steps are controlled in part by gas path control valves in gas paths of the filling points 4.1, 4.2.
As indicated in
Referring to
Referring again to
The rotor 3 includes an upper disc-like rotor element 3.1. Ring channels 17, 18 at the top of rotor element 3.1 feed gas or provide a vacuum for all filling elements 7.
The upper disc-like rotor element 3.1 also forms a top seal for an aseptic space 16. Wall elements, which are not shown, form the sides and base of the aseptic space 16, thus completing the separation of the aseptic space 16 from the atmosphere.
The filling elements 7 are mounted in openings around the periphery of the rotor element 3.1 in such a way that a lower section of the filling element 7 protrudes into the aseptic space 16. This lower section includes an associated container holder 8. An upper region of the bottle forms the bottle's opening. This region moves through the aseptic space 16 during filling.
Referring now to
The inner gas paths 20.1 do not have any control valves. These inner gas paths 20.1 are therefore uncontrolled. Within a filling element 7 or within a housing 9, only these uncontrolled inner gas paths 20.1 are present.
The inner gas paths 20.1 of the two filling elements 7 of each first filling point pair 4 open out into the outer gas paths 20.2. As a result, the gas path control valve 19 controls both filling elements 7 of a first filling point pair 4 simultaneously.
In some embodiments, the gas path control valves 19 are pneumatically operable valves that are actuated by a valve block 21 having electrically controlled actuators. A machine controller 22 controls these actuators. The valve block 21 also controls the liquid valves 14 that open and close the filling elements 7.
Control over the various valves depends at least in part on the how much filling material flows into bottles 2 during the filling phase. A flow meter 23 measures this quantity and transmits pertinent data to the machine controller 22. In some embodiments, the flow meter 23 is a magnetic induction flow meter,
As long as they are accurately configured, the filling elements 7 will have the same filling rate. It is therefore possible to use only one flow meter 23 for each first filling point pair 4. This flow meter 23 is placed in a product line 11 that connects the tank 12 to either one of the two filling elements 7.
The double-valve control system described herein offers synchronous valve activation under virtually identical process conditions. For example, for each pair of filling elements 7, the filling pressure, the fill level in the product tank 12, and the temperature will be the same or very close to the same. This means it is possible to use only one flow meter 23 to provide one measurement signal for two filling points 4.1, 4.2. Additionally, there is only one control signal per first filling point pair 4.
Previous attempts to provide one flow meter 23 for two filling points 4.1, 4.2 have failed because of unpredictable short-term changes in the process parameters. These changes have different effects on the respective filling points 4.1, 4.2, the results of which are significant differences in the filling characteristics of even immediately adjacent valves. As a result, known filling machines have a separate a flow meter 23 at each filling point 4.1, 4.2.
In the illustrated embodiment, the gas path control valves 19 and the outer gas paths 20.2 of all first filling point pairs 4 are part of a multiple control-module 24. The multiple-control module 24 has separate gas path control valves 19 and outer gas paths 20.2 for each first filling point pair 4. Each filling element 7 is connected to one of these gas path control valves 19.
In an alternative embodiment, instead of a multiple-control module 24, a single control-module controls the filling points. Like the multiple-control module, the single-control module has gas path control valves 19 and outer gas paths 20.2 that can be used for the first filling point pairs 4.
The architecture described above results in a modular layout and design. This modularity arises whether the filling elements 7 are used with the multiple-control modules 24 or with single-control modules. This modular layout simplifies the replacement of faulty components, such as a faulty filling element 7, a faulty multiple-control module 24, or a faulty single-control module. The modular configuration also makes it possible to fit specially constructed filling elements 7 with either a standard multiple-control module 24, a standard single-control module, a non-standard multiple-control module 24, or a non-standard single-control module with standard filling elements 7. This simplifies conversion of the filling machine 1 for special filling processes.
Referring now to
The outer gas channels 20.2 are provided on this ring 24.1. In addition, the gas path control valves 19 are arranged on top of the ring 24.1. These gas path control valves 19 are offset radially inwards relative to the vertical machine axis MA opposite the filling element housing 9 associated with the control valve 19.
In operation, a bottle 2 is lifted up and pressed against the filling element 7 to form a seal around the delivery opening 13. This requires application of a force. The source of at least part of this force is none other than the internal pressure present in the bottle 2 itself during the filling process.
A gas channel 25 in the filling element 7 communicates pressure between the bottle's interior and a pneumatic actuation element 26 disposed on top of the ring 24.1. Each pneumatic actuation element 26 is part of the multiple-control module 24.
An actuating element 26 includes a bellows 26.2, a housing 26.3, and a cam follower 26.4. The bellows 26.2 forms a pressure chamber 26.1. The housing 26.3 surrounds the bellows 26.2. The cam follower 26.4 is axially guided within the housing 26.3.
During the filling process, a lower opening connects the gas channel 25 with the bottle's interior and discharges above into the pressure chamber 26.1 of the pneumatic actuating element 26.
Referring to
In some embodiments, the actuating element 26 also has a spring that pre-tensions the container holder 8 in its upper lifting position. The actuating element 26 and the lifter rod 27 form part of a lifter device 28, shown in
In the embodiment shown in
Aside from the foregoing differences, the second filling point pair 4a shown in
In an alternative embodiment, shown in
The lifter rod 27 and the actuating element 26 for the container holder 8a are offset radially inwards from filling elements 7, in such a manner that the radial distance of the actuating element 26 from the machine axis MA is somewhat less than the corresponding radial distance of the lifter rod 27 whose upper end is connected by a cross member 31b with the actuating element 26 or with its cam follower. Once again, a cam roller 29 mounted at the center of the cross member 31b freely rotates.
Among the features that the first, second, and third filling point pairs 4, 4a, 4b have in common is a multiple-control module 24 that has gas path control valves 19 with controlled outer gas paths 20.2, while the filling elements 7 themselves have only uncontrolled inner gas paths 20.1. The embodiments also have in common the fact that the multiple-control module 24 defines a modular architecture that includes a ring 24.1, gas path control valves 19 and actuating elements 26.
The embodiments illustrated in
The fourth filling point pair 4c includes two filling points 4.1, 4.2, each of which has an associated filling element 32. A common control module 33 controls the gas paths. However, instead of being formed by a ring common to all filling point pairs, the illustrated common control module 33 is formed by a discrete module body 34 for each filling point pair 4c.
In the illustrated embodiment, the discrete module body 34 is a plate that has an outer gas path 20.2 that contains the gas path control valve 19. The gas path control valve 19 controls a connection between the outer gas path 20.2 and an annular gas channel 35, best seen in
First and second union openings 20.2.1, 20.2.2 effect a connection between outer gas paths 20.2 and the associated inner gas path 20.1 in the housings of the filling elements 32 shown in
In each case, a filling element 32 and the discrete module body 34 lie against each other on a flat surface that is oriented preferably square to the vertical machine axis. A seal 36 provides a sealed transition between the outer gas path 20.2 and the associated inner gas path 20.1. The opening cross-section of the seal 36 is greater than the cross-section of either the first union opening 20.2.1 or the second union opening 20.1.1. The common control module 33, or its discrete module body 34, also has a union opening 37 for connection to the annular gas channel 35.
An advantage of the modular structure of the fourth filling point pairs 4c is that filling point pairs 4c with the same pitch distance TA between filling elements 32 can be adapted for use on filling machines with different rotor diameters and with different pitch circle radii. This is illustrated by comparing
A center-to-center distance X between union openings 20.1.1 varies because of different pitch circle sizes. However, this variation can be compensated for because the seal opening 36.1 is significantly larger than the cross-section of at least the first union openings 20.1.1, as shown in
Different pitch distances TA of filling points 4.1, 4.2, i.e. center-to-center distances of filling elements 32 that form these filling points 4.1, 4.2 around the periphery of rotor 3, will then require common control modules 33 in which the center-to-center distance of union openings 20.2.1 is adjusted to match the respective pitch distance.
The invention has been described hereinbefore by reference to embodiments. It goes without saying that numerous variations as well as modifications are possible without departing from the inventive concept underlying the invention.
Number | Date | Country | Kind |
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10 2013 101 812 | Feb 2013 | DE | national |
10 2013 101 813 | Feb 2013 | DE | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2014/000108 | 1/16/2014 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2014/127879 | 8/28/2014 | WO | A |
Number | Name | Date | Kind |
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9302895 | Clusserath | Apr 2016 | B2 |
20050045244 | Hartness et al. | Mar 2005 | A1 |
20050284731 | Hartness | Dec 2005 | A1 |
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Number | Date | Country | |
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20160009534 A1 | Jan 2016 | US |