The present invention relates to the handling of articles, such as beverage containers moving at high speed in modern production facilities. Of special interest is the use of the invention in the food and beverage industry and in particular the handling of bottles containing alcoholic and non-alcoholic beverages. Examples of such beverages include beer and beer-based drink such as shandies; coolers and low or non-alcoholic beers; non-alcoholic soft drinks such as colas; water; fruit juices and the like.
Beverage industries are major users of bottles and the beverage industry in many countries utilize returnable and re-usable bottles for both cost and environmental protection reasons. Such systems require return of bottles and these are collected into a “float” from which users draw when needs arise. In some countries, for greater efficiencies, the major brewers have a “common” or “standard” bottle. Not only does the bottle have a set internal volume, it has the same design and external dimensions. This should result in all bottles in the float being identical. However, many drinks, including beers, are in fact sold in bottles which, although varying from the “standard”, do not do so significantly, and hence are not so differentiable therefrom to be readily noted and removed. However, they do so sufficiently to interfere with and jam, for example, the cleaning equipment used to effect re-use of the bottles. The variances may for example be in height but especially diameter and at one or more zones along the height of the bottle, etc. Of course, some bottles are significantly different from the standard bottle and they can be readily identified and removed. In any event, all such bottles which differ from a chosen “standard” are therefore “non-standard” or “foreign” bottles, and when inadvertently included in the float are quite sufficient to cause serious, costly and continuous problems. A “standard” bottle as used herein means a bottle of a set design and dimensions chosen to be used by a number of bottlers for containing a beverage for sale at retail and which bottle is returned directly or indirectly to the beverage bottler for reuse. There are usually a number of such bottles as well as other types of bottles, such as non-returns; returns and non-reuse, etc i.e. non-standard bottles circulating in any geographical area. Consequently, unavoidably, the float of bottles created from returns although generally being made up mainly of the desired standard bottle, also includes a minority of the dimensionally different non-standard bottles. In summary the non-standard bottles in the float are not greatly different, the differences including for example a small difference in main body diameter of say up to half a centimeter; a difference in shoulder height; a “bulge” in the base region or at the label location, and similar dimensional differences.
In the beverage industry, product units such as bottles are often transported within production facilities in lines or streams in single file at high speed using conveyor systems. In some instances, the pathway defined by the conveyor is not much wider than the moving container but is sufficient to allow for free movement of the container along the conveyor. The conveyor is set up such that in many sections the containers generally travel along it in single file adjacent to one sidewall or rail of the conveyor. This generally occurs even if the width of the conveyor is greater than the width of the container. For example, empty beer bottles, very common articles to which the present invention relates, are generally required to be transported from depalletizers to a washing station, through a rinsing station to an automated filling device, often at rates of up to 1,000 or more bottles per minute. Obviously, in an operation involving so many bottles processed at those rates, there are going to be a number of bottles which are commercially unacceptable for various reasons. In addition to such returned, non-standard bottles, following being filled, a standard bottle may be under-filled, or over-filled, with beer or the bottle label may be misaligned or even totally missing. Such bottles are also not acceptable and must be separated from the acceptable bottles prior to the latter proceeding to a packaging station. There are many known systems for inspecting the stream of bottles and detecting any such unacceptable or defective bottles (refer for example to U.S. Pat. Nos. 5,979,635 and 6,043,504). Once any unacceptable bottle has been detected, it must be removed from the line or stream. It will be appreciated that commercial reality means that the production line cannot be stopped or generally even slowed down each time an unacceptable bottle has to be removed. It is also important to note that although there is often a constant small space between adjacent bottles in the moving line such bottles might be, and often are, in contact. This clearly complicates the removal of each unacceptable bottle since it must be removed without affecting the speed or direction of movement of the two adjacent and acceptable bottles and the effect the latter bottles may have on bottles adjacent to them and so on. Moreover, although in some instances as the present, simple rejection to a rejection bin of unaccepted bottle may be all that is required, there are instances when it is desirable to direct rejected bottles to one of several possible locations and in a controllable manner; in essence, sort the bottles. For example, a bottle, which has been found to have lower than the prescribed amount of beer, (i.e. it is a “low-fill”) might be re-directed to a station which empties the bottle of beer and the beer and the bottle are reclaimed. In another case a bottle with the label missing could result in the rejected bottle being returned to the labeller. Alternatively, there may be a need to collect non-standard bottles.
Many commonly used rejection or sorting systems involve an actuator assembly which includes a piston carrying a bottle-contacting member or pad which assembly is located adjacent the side of the conveyor, the actuator member being arranged to extend across the conveyor at right angles to the direction of travel of the bottles and to be retracted along the same path. As it advances, the pad contacts the body of the moving bottle to be diverted with more or less force depending on a number of factors. The bottles are essentially struck out of the moving line of bottles hopefully leaving the adjacent, and especially the immediately following, bottle unaffected as regards its velocity and direction. The diverted bottles may be directed off the conveyor adjacent to a collection receptacle or redirected on to another conveyor adjacent the first conveyor; refer, for example, to U.S. Pat. No. 3,133,640. Systems of this type are called “boppers” or “bang-bang” systems because of their mode of action. U.S. Pat. No. 5,979,635 discloses a system of using a type of diverter assembly of the bopper-type as described above but with provision to extend the servo activator in a controlled pre-determined manner to a position adjacent to the article to be deflected where, preferably, it pauses prior to initiating the actual diversion of the article according to an ejection waveform. Such systems are quite complex and require significant maintenance.
It is an object of the present invention to provide a simple and inexpensive contact method and device for the detection and optional removal in a single action of non-standard bottles from a line of standard and non-standard bottles travelling in single file at speed on a conveyor.
The present invention utilizes physical differences between standard and non-standard bottles to rapidly and efficiently via mechanical means detect and thereby subsequently handle, e.g. reject the non-standard bottles from a stream comprising both types of bottles. A bottle detection member is arranged to extend into the path of the line of the bottles and be maintained at a pre-determined height and lateral distance, which allows a standard bottle to pass undetected but for a non-standard bottle to be detected by contacting the member and then following identification, be subjected to a second action such as rejection or sorting. In one embodiment, the detection member may be a simple panel, strip or bar of material, a metal such as, for example, steel or a plastics material such as polyamide plastic, is arranged to extend over a single file conveyor transporting a stream of bottles. The extent of overlie and the vertical location thereof is very important and is determined by the physical difference between the standard bottle and the non-standard bottles to be detected. For example, if the shoulder of the standard bottles is lower than that of the non-standard, then the bar can be arranged to be located over the conveyor track a lateral distance and at a height which allows the shoulders of the standard bottle to pass under—and that bottle proceed along the conveyor undetected or unhindered—whilst the shoulder of the non-standard bottles strikes the detection bar and the bottle is detected. There may be more than one detection member, for example, one may be positioned to contact a non-standard bottle having a larger diameter neck than the standard bottle and a second can be positioned at the same or another station to contact a non-standard bottle which has a higher shoulder than the standard bottles.
Although the detection member may preferably contact the bottles at any position intermediate the height of the standard bottle in the stream, for practical reasons, preferably the bar is positioned to be contact by the bottle above the height of the wall of the conveyor along which the bottles are traveling since the device is usually located adjacent the conveyor and changing the interior wall of the sidewall along which the bottles are traveling and may contact is not preferred. In any event, the deflection of the detection member is itself detected by appropriate sensing means.
Various sensors can be used to detect deflection by rotation, bending or other movement of the detection member. For example, a mechanical sensor such as a simple micro switch. This is a mechanical device that contains two internal contacts. Microswitches are modular, inexpensive to produce, dust and contaminant resistant and “metered”. By “metered” is meant that it clicks at the same point when the actuator is depressed. The consistency is maintained not only for the lifetime of the switch but for other microswitches of the same model. They are therefore easily maintained and replaced. Such devices may be obtained from many manufacturers including Honeywell Inc at 11 West Spring Street, Freeport, Ill. 61032. Photoelectric switches may also be used as sensors, a major advantage of the photoelectric switch being that it detects, but does not contact the moving detection member. More information regarding photoelectric devices can be found at the website www.theproductfinder.com/sensors.phosen.htd which site also includes a list of manufacturers or suppliers of the devices. In any event, it is preferred that a through beam rather than a reflective sensor is used since it would possibly be more effective in view of the adverse conditions in facilities where devices of the present invention are used, such as dust or dirt.
The device of the present invention may be located at any position in the process where there is a single-file conveyor section and bottles travel close or adjacent to one wall thereof. For example, a section where there is already in place, a bottle ejection or rejection system, e.g. at the filler or after the labeller. One preferred location is prior to the washer not only because non-standard bottles can cause shutdown of the washer but this eliminates the bottle prior to their being processed and thus incurring unnecessary continuing processing costs.
It might be noted that a non-standard bottle—if any—which falls totally within the profile of the standard bottle will not be detected by the present system but would probably be readily and visibly discernable and be removed well prior to it being included in the float.
In one aspect the present invention provides a device for detecting non-standard bottles in a stream comprising standard and non-standard bottles traveling on a conveyor along a path through a station comprising a bottle detection member at said station and extending into said path and adapted to be contacted and deflected from a base position only by a traveling non-standard bottle and, following passage of said station, return to said base position, and sensing means adapted to detect a deflection movement of said member and then generate a detection signal.
Preferably, the detection member is adapted to contact said bottle intermediate the height of the bottle.
It is preferred that the laterally outer most-edge i.e. the edge overlying the conveyor track is shaped to conform to at least part, especially the shoulder and/or neck part, of a standard bottle.
A single detection device, by incorporating two separate detection members each provided with associated sensor means and circuitry can be used to detect two different non-standard bottles.
In a further embodiment, two or more detection devices can be installed on the same conveyor track, one downstream of the other, on the same or different sides.
In either case, the created signal may be provided to a single diverter device such as a bottle ejector or two or more such devices, downstream of said detectors to allow sorting of the bottles.
In a further embodiment, the present invention provides a novel detection device as described above in combination with bottle diverter to form a rejection or sorting device and system.
In a further embodiment, the invention provides a system for treating returnable and reusable standard beverage bottles and re-filling same with a beverage, which bottles are transported to the various activity stations in a single file wherein standard bottles are returned for use in combination with a number of non-standard bottles are returned for reuse, the latter being required to be separated out, the improvement comprising detecting and ejecting or removing foreign bottles as described above and processing said standard bottles to a beverage filled condition.
The present inventions will be further described but not limited by reference to the accompanying drawings in which:
In the following, like numbers indicate similar parts in the various drawings and a single arrow indicates direction of travel.
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However if it is desired to collect the rejected bottles in a good condition, the rejecter is preferably one that can handle the bottles in a more controlled and consistent manner. Such a device is claimed in Assignee's pending U.S. patent application Serial. No. 09/891,616 (Frederick Linton) the contents of which application are incorporated herein in its totality and the combination of the herein described mechanical detector and a container rejecter device constitutes another aspect of the patent invention.
To summarize the operation, the non-standard bottle 13 has a neck 15 of greater diameter than that of standard bottle 12 and the neck does not match the profiled edge 44 resulting in panel 42 being contacted by and rotating clockwise under the influence of bottle 13 as it passes through the detection station. The rotation results in contact 50 activating the microswitch contact 46 which results in a signal passing to rejection circuit 31. In its turn, and following a short delay, a signal is sent to activate rejection device 39 which responds by urging the then arrived detected bottle 13 out of line 21 and into reject bin 28. In the meanwhile, detection panel 42, following passage of the non-standard bottle 13, reverses under the influence of spring 50 and returns rapidly to it neutral position to resume its detection function. Any tendency to go past the neutral position is precluded by backstop 48. The result is rapid return to the pre-use neutral location to enable accurate detection of the physical differences been standard and non-standard bottles to be repeated rapidly and repeatedly at speed.
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In operation in a beer bottle recycle and reuse system, bottles are returned, usually in the cartons they were contained in when originally purchased full, to a retail store or other collection centre from where they are returned to the brewing facility for reuse. Usually they are stacked on pallets, containing about 90 cartons each containing 24-341 mL/12 oz “pint” bottles per carton. Commercially available equipment depalletizes the cartons, removes the bottles therefrom to form a float which supplies a conveyor which transports the bottles to a washing system. Following washing, they are transported again by conveyor systems to a filling station, then a pasteurization station and finally to packaging. In a number of these stations, a non-standard bottle causes serious problems leading in many instances to line shutdown. Obviously, it is preferable that the non-standard bottles be removed at the earliest stage of the recycle process and this is following being removed from the cartons in which they had been returned. Bottles having an obviously very different design etc. are readily noted and removed, especially those with neck and body diameters or heights markedly different to similar characteristics of the chosen standard bottle.
Operation
It is believed that the operation of the device and the system of the present invention is evident from the above but a brief summary is as follows.
A stream 21 of bottles, the major proportion of which are standard bottles 12 and some non-standard bottles such as 13 or 14, traveling at high speed approach one—
In both cases, the deflection of panel 44 triggers an associated microswitch or photosensor which via circuitry means 31, initiates a delay calculated to allow the detected bottle to travel to a bottle diverter 39. The bottle is then ejected or otherwise transferred to a bin 28 or another conveyor 25 or 27. In either case, panel 44, following passage of bottle 13 immediately returned to its base or neutral position effectively immediately to be available to repeat its function.
Variations of the basic device can be used to sort bottles, refer to
The present invention therefore presents a simple system for detecting and handling undesirable non-standard bottles contained in a float of standard and required bottles. The detection is effected in a simple mechanical manner at low cost with components which are inexpensive, hardy, require little maintenance and take up little space in the facility. Moreover, the device and system are readily adjusted to accommodate a change in non-standard bottles to be handled. Obviously, the device and system can be sued to advantage to handle articles similar to the bottles as described above.
Number | Date | Country | Kind |
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2,441,687 | Sep 2003 | CA | national |