This disclosure relates to production of product containing pouches employing horizontal form, fill and seal packaging machinery such as illustrated, for example, in U.S. Pat. No. 5,699,653, which is incorporated by reference. Typically, the output of such a machine comprises a bandolier of filled pouches connected along a common side seam seal. The bandolier is processed on a remote knife mechanism for separation into individual pouch products.
Remote knife mechanisms are well known and widely used. An aspect of operating such equipment is the need to maintain proper registration between the travelling bandolier of pouches and the cutting blades of the knife mechanism. In an embodiment, this function is manual and subject to the frailties of operator intervention.
The system of the present disclosure provides automatic registration control. It utilizes optical monitoring indicative of the positional relationship between the bandolier and the cutting elements. Recognition of a deviation generates an output signal delivered to mechanism responsive to adjust the input flow of pouches relative to the cutting elements. The system includes electronic sensing, with image capture, data processing with a programmable controller (PLC), output signal generation and mechanical adjustment, through responsive mechanism.
In an aspect, a system for controlling registration on a pouch knife machine, of a longitudinally extending bandolier of content containing pouches separated by transverse seal seams moving along a feed path, with each pouch having a measurement reference. The machine includes a knife mechanism, a friction drag mechanism, and a friction drag adjustment mechanism. The knife mechanism includes a major knife hub mounted along the feed path and having a plurality of spaced apart blades having an outer edge, a minor knife hub having at least one blade, with the minor knife hub cooperating with the major knife hub to sever individual pouches from the bandolier at the seal seams, and the drive mechanism drives the major knife hub and the minor knife hub in a synchronous manner. The system includes an optical reference, an optical image sensor, and a controller. The optical reference is indicative of the location of cooperation between said blades of said major knife hub and minor knife hub and the optical image sensor generates position signals indicative of a position relative to the optical reference of the measurement references of moving pouches along the feed path. The controller is configured to store a target position for the measurement reference relative to the optical reference indicative of a desired cutting location within a pouch seal seam, store an operating range for the target position, receive position signals from the optical image sensor, and determine an actual position of the measurement reference relative to the optical reference based upon the position signals. The controller is further configured to determine an alignment input based upon the actual position of the measurement reference relative to the optical reference, determine an alignment difference between the target position and the alignment input, and generate an adjustment command to change the position of the bandolier along the feed path after the alignment difference exceeds the operating range for the target position.
In another aspect, a method of controlling registration on a pouch knife machine of a longitudinally extending bandolier of content containing pouches separated by transverse seal seams moving along a feed path with each pouch having a measurement reference includes maintaining driving engagement between a major knife hub and the bandolier along the feed path, storing a target position for the measurement reference relative to an optical reference of an optical image sensor disposed along the feed path, with the target position corresponding to a cutting location of the major knife hub and a minor knife hub that interacts with the major knife hub to sever pouches from the bandolier, and storing an operating range for the target position. The method further includes receiving position signals from the optical image sensor, determining an actual position of the measurement reference relative to the optical reference based upon the position signals, determining an alignment input based upon the actual position of the measurement reference relative to the optical reference, determining an alignment difference between the target position and the alignment input, and generating an adjustment command to adjust a position of the bandolier along the feed path after the alignment difference exceeds the operating range for the target position.
The present disclosure is illustrated by way of example and is not limited in the accompanying figures in which like reference numerals indicate similar elements and in which:
The packaging machine creates spaced side seam seals 26 and temporarily creates a fill opening to the interior of the pouch along top edge 28. After filling the pouch, the top horizontal edge is sealed, closing the fill opening and sealing the pouch.
The remote cutting mechanism 10 of this disclosure, discussed in detail below, forms side edges 30 of each pouch 22 and, in doing so, separates the bandolier 20 of pouches through the common side seam seal 26 to form the individual pouches 22. As described in more detail below, interacting blades of the knife mechanism 10 form the pouch side edges 30 of adjacent pouches optimally by bisecting the connecting side seam seal 26 to form leading side seam seal 26L and trailing side seam seal 26T.
The terms “leading” and “trailing,” “forward” and “rearward,” “advanced” and “retarded,” as used herein, are in reference to the direction of travel of bandolier 20 (depicted by arrow “A”), as is the term “longitudinal.” “Wider” and “narrower” and “width” refer to a dimension along the longitudinal extent of pouch 22 between side edges 30 of the bandolier 20.
In the pouch-forming process, the pouch material is usually printed with product indicia and other information. As illustrated in this disclosure, registration marks or “eyemarks” 32 may be printed in spaced intervals to identify the appropriate location for forming side edges 30. In the drawings, registration marks 32 include leading edge 32L and trailing edge 32T.
The knife mechanism, generally 50, is graphically illustrated in
Referring to knife mechanism 50, the major knife hub 60 is segmented into a plurality of stations by radial blades 62. As best seen in
The minor knife hub 70 can include a lesser number of the radial blades 72 than major knife hub 60. Each blade 72 includes a radial outer cutting edge 74 that coacts, in shear, against a trailing radial edge surface 66 of one of the blades 62 of the major blade hub 60 to create the side edges 30 on each pouch by severing the common side seam seal 26 to form the trailing side seam seal 26T of one pouch 22 and the leading side seam seal 26L of the subsequent pouch 22. More specifically, the cutting edge 74 of one of the radial blades 72 of the minor knife hub 70 interacts with the trailing radial edge surface 66 of one of the radial blade 62 of the major blade hub 60 to cut one of the common side seal seams 26 between adjacent pouches 22. In doing so, each cutting operation creates a leading side seam seal 26L and a trailing side seam seal 26T of adjacent pouches 22 from the bandolier 20. The hubs 60 and 70 are positioned relative to each other and driven by a drive mechanism synchronously to coact such that the minor hub blades 72 sever pouches 22 from the bandolier 20 in a scissor-like fashion.
From the foregoing, it may be understood that the radial blades 62 of the major knife hub 60 serve two purposes. First, the outer edges 64 operate to carry or pull the bandolier 20 of pouches 22 from the bandolier supply, along the feed path 81, and to the major knife hub 60. Second, the trailing radial edge surfaces 66 of the radial blades 62 of the major knife hub 60 cooperate with the cutting edges 74 of the radial blades 72 of the minor knife hub 70 to sever the pouches 72 from the bandolier 20.
Powered rotation of the major knife hub 60 advances the bandolier 20 along the pouch channel or feed path 81 on a line tangent to the major knife hub 60 at radial outer edges 64 of blades 60. More specifically, in the illustrated remote knife mechanism 10, a strap tensioning device 110 (
As best seen in
The remote knife mechanism 10 further utilizes the registration marks 32 to dynamically adjust the location at which the common side seam seal 26 is cut. To do so, the bandolier is positioned relative to the major hub 60 so that a registration mark 32 generally overlies the edge or land 64 of one of the major hub blades 62. Ideally, as an optimum position to be achieved with the system of this disclosure, the trailing radial edge surface 66 is positioned to bisect the registration mark 32. For simplification of the explanation, it has been assumed that each registration mark is printed on the bandolier 20 in a position in which the desired aligned cut would bisect the registration mark.
It is understood that the registration mark could be printed in a repetitious pattern anywhere on the pouch. For example, the registration marks 32 may be printed anywhere on the bandolier 20 provided that they can be monitored by the optical image sensor 216 as described below. In the depicted embodiment, the registration marks 32 are depicted as rectangles located along the bottom edge 24 of the bandolier and ideally centered within the common side seam seal 26. In another embodiment, other indicia such as logos, writing, or other printed shapes, regardless of position on the bandolier 20, may be used as the registration marks provided that they are included in a repeating pattern on or associated with each pouch 22.
Various parameters of pouch making affect the minimum force required to maintain the driving relationship between the bandolier 20 and the outer edges 64 of the major hub blades 62. These include the pouch material, the pouch configuration, the contents of the pouch, manufacturing tolerances, environmental conditions, and other factors. The impact of these parameters are well known and accommodated by appropriate setting of the radial forces controlling advancement of the bandolier 20.
Advancement or driving of the bandolier 20 results from frictional contact between the surface of bandolier 20 at the side seam seals 26 and the edges 64 of the rotating blades 62 of the major knife hub 60. Inherent in this relationship is a degree of rearward slip (counter-clockwise as compared to arrow “B” In
It will be understood by one skilled in the art that the width or distance between the side edges 30 of a pouch that is over-filled will be less than the width of an ideally filled pouch and the width or distance between the side edges 30 of a pouch 22 that is under-filled will be greater than the width of an ideally filled pouch. Reliable control of the slippage is an important element of the operation of the remote knife mechanism 10.
Longitudinal positioning of the travelling bandolier 20 relative to the major hub 60 and minor hub 70 to ensure uniform side seam seals 26T, 26L (resulting from cutting at the center of the common side seals 26) is controlled through application of a combination of frictional drag forces upon the exterior surface of the travelling bandolier of pouches 22.
Modification or adjustment of the frictional drag on the travelling bandolier 20 of pouches can be imparted by any suitable device. For example, a roller (not shown) with adjustable frictional resistance could be positioned in rolling contact with the exposed upper surface of the travelling bandolier. A mechanism could be employed to adjust the rotational resistance in accordance with the amount of pouch “slippage” desired or necessary. Such a roller can be made of rubber or similar material to prevent damage to the pouches. Another option contemplated could include a timing belt configuration (not shown) in resistive contact with the travelling bandolier 20, again, arranged to adjust the drag imposed, based on recognized alignment requirements.
In the depicted embodiment, two separate components for controlling slippage or drag are employed. Referring to
The illustrated paddle tensioning device 90 includes a support leg 91, a cantilevered arm 92 pivotably mounted on the support leg, and a paddle 93 with a flat surface 94. The paddle 93 can be pivotably mounted on the support leg 91 so that the flat surface 94 faces and engages the bandolier 20 as it moves along the feed path 81 to exert a force perpendicular to the bandolier.
The paddle tensioning device 90 further includes an actuator 95, such as a pneumatic actuator, that is operative to adjust the amount of pressure exerted on the bandolier 20 by the surface 94 of the paddle 93. The paddle tensioning device 90 may be configured so that a linear relationship exists between the force imparted by paddle device 90 and the resulting position of the cut of the side edges 30 in relation to the eyemark or registration mark 32. In other words, linearly increasing or decreasing the force imparted by the paddle tensioning device 90 will result in a linear increase or decrease in the relative position of the location of the edges 30 relative to the registration mark 32.
The illustrated belt tensioning device 110 includes a flexible belt or strap 111 and a belt guide system 112 operative to position the belt adjacent the bandolier to exert an adjustable radial force (i.e., perpendicular to the bandolier 20) on the outer surface of the bandolier 20 at a portion of the perimeter of the major knife hub 60 defined by the blade edges 64. As depicted, the belt guide system 112 includes a lower guide 113, a first roller 114 disposed along the feed path 81 configured to engage the bandolier 20 upstream from the major knife hub and a second roller 115 spaced from the feed path.
The belt tensioning device 110 further includes an actuator 116, such as a pneumatic actuator, that is operative to adjust the amount of pressure exerted on the bandolier 20 by the belt 111. As with the paddle tensioning device 90, the belt tensioning device 110 may be configured so that a linear relationship exists between the force imparted by the belt 111 and the resulting position of the cut forming the side edges 30 in relation to the eyemark or registration mark 32. In doing so, linearly increasing or decreasing the force imparted by the belt tensioning device 110 will result in a linear increase or decrease in the relative position of the location of the side edges 30 relative to the registration mark 32.
In some known arrangements, the paddle tensioning device 90 and the strap tensioning device 110 are associated with manually adjustable mechanisms, such as a spring or air cylinder. The amount of force that can be imparted to the travelling bandolier 20 through manual adjustment of these mechanisms is based on observations of the finished pouches by a machine operator.
The operation of the remote cutting mechanism 10 may be controlled by a control system depicted generally at 200. The control system 200 may include an electronic control module or controller 201 and a plurality of sensors associated with the remote cutting mechanism 10 that provide data and input signals representative of various operating parameters of the remote cutting mechanism 10. The control system 200 may operate by using the data from the various sensors as discussed in further detail below.
The controller 201 may be an electronic controller that operates in a logical fashion to perform operations, execute control algorithms, store and retrieve data and other desired operations. The controller 201 may include or access memory, secondary storage devices, processors, and any other components for running an application. The memory and secondary storage devices may be in the form of read-only memory (ROM) or random access memory (RAM) or integrated circuitry that is accessible by the controller. Various other circuits may be associated with the controller 201 such as power supply circuitry, signal conditioning circuitry, driver circuitry, and other types of circuitry.
The controller 201 may be a single controller or may include more than one controller disposed to control various functions and/or features of the remote cutting mechanism 10. The term “controller” is meant to be used in its broadest sense to include one or more controllers and/or microprocessors that may be associated with the remote cutting mechanism 10 and that may cooperate in controlling various functions and operations of the mechanism. The functionality of the controller 201 may be implemented in hardware and/or software without regard to the functionality. The controller 201 may rely on one or more data maps that may be stored in the memory of controller. Each of these data maps may include a collection of data in the form of tables, graphs, and/or equations.
The control system 200 and controller 201 may be located at the remote cutting mechanism 10 or may be distributed with components also located remotely from the remote cutting mechanism. The functionality of control system 200 may be distributed so that certain functions are performed at the first machine 11 and other functions are performed remotely.
As stated above, the remote cutting mechanism 10 may be equipped with a plurality of systems and sensors that provide data indicative (directly or indirectly) of various operating parameters of the mechanism. The term “sensor” is meant to be used in its broadest sense to include one or more sensors and related components that may be associated with the remote cutting mechanism 10 and that may cooperate to sense various functions, operations, and operating characteristics of the mechanism.
The control system 200 further includes a registration monitoring and control system generally indicated at 205 that provides automatic adjustment of pouch registration relative to the radial blades 62 of the major knife hub 60. The registration monitoring and control system 205 utilizes an optical image capture system 210 to acquire data indicative of the position of the registration mark 32 as the registration mark approaches the minor knife hub 70. The controller 201 is operative to control the relationship between the position or registration of the bandolier 20 and the knife mechanism 50.
The controller 201 is further operative to determine whether the position of the registration mark 32 varies from the desired position by more than an operating threshold. If the distance between the registration mark in the desired position exceeds the operating threshold, the controller 201 is configured to generate an adjustment command to modify the force on the bandolier 20 and thus alter the relationship between the registration mark 32 and the desired position. Notably, the deviation recognized by the vision signal acquisition may also be employed to effect shutdown of the remote knife mechanism 10 based on recognition of an excessive deviation.
The controller 201 can include a monitor and keyboard 204 (
Another input setting may be a “dead band” or operating range within which no adjustment directive will be initiated. More specifically, deviation from the desired or target position is to be expected and no adjustment to the tension on the bandolier 20 is made provided that the actual position of the measured edge of the registration mark 32 is within the operating range or threshold. This operating range minimizes hysteresis or oscillation of the adjustment function.
A further input setting may be a specified adjustment amount that designates the magnitude of change initiated, should a deviation be recognized that requires repositioning of the bandolier 20 relative to the rotary blades 62 and 72 by the actuators 95 and 116. In some instances, such adjustments are made in one pound per square inch increments (PSI). Still a further input setting may designate when to adjust the force applied by the paddle tensioning device 90 to change the slippage of the bandolier 20 and/or when to adjust the force applied by the belt tensioning device 110 to change the slippage of the bandolier. Each of the input settings can be set or stored within the controller 201 or accessed by the controller from a remote source.
Deviations from alignment are determined and evaluated by the controller 201. It is the deviation of formation of edge 30 relative to registration mark 32 that dictates modification of the amount (and direction) of slippage of bandolier 20 necessary to properly position the bandolier 20 relative to the major knife hub 60.
The control system 200 includes an optical image capture system 210 for determining the position of the pouches 22 of the bandolier 20 relative to a pre-established reference scale location. More specifically, the optical image capture system 210 can include any type of optical image sensor 216, such as one or more cameras, configured to generate optical image data indicative of the position of the bandolier 20. A reference scale 212 (
The optical image sensor 216 is actuated by a position recognition mechanism comprising a trigger disc 220 and a trigger sensor 230, seen in
The trigger sensor 230 views the path of the apertures 222 in the rotating disc 220 and generates a signal as each aperture is recognized. This signal initiates the function of the optical image sensor 216 in a periodic pattern corresponding to each registration mark 32 becoming aligned with the image acquisition field 211 (
As seen in the drawings, particularly
In an embodiment, the optical image sensor 216 can be configured as a “smart camera.” That is, it can have data processing capability to convert the acquired images to an absolute numerical function for delivery to the controller 201. In such a configuration, the optical image sensor 216 includes the capability to provide an internal reference scale, generally designated 212 in
The reference or target position of the measurement edge of the registration mark 32 may then be associated with a numerical value corresponding to a location on the reference scale 212. In doing so, the location of the reference scale 212 can be adjusted, internally of the optical image sensor 216, relative to the reference or target position of the measurement edge of the registration mark 32 at the instant the optical sensor acquires an image (as triggered by trigger disc 220 and trigger sensor 230). For example, in some embodiments, it may be desirable to position the reference or target position of the measurement edge of the registration mark 32 at the center of the reference scale 212. In another embodiment, as depicted in
In operation, upon triggering the optical image sensor 216, optical image data from the optical image sensor is delivered to controller 201. The controller 201 can determine whether the measurement edge of the registration mark 32 is within the dead band or operating range surrounding the reference or target position on the reference scale 212. If the measurement edge of the registration mark is within the operating range, the remote knife mechanism 10 may continue to operate without change as the pouches 22 are separated from the bandolier 20. If the measurement edge of the registration mark 32 is outside the operating range, the controller 201 can generate an adjustment command so that one or both of the paddle tensioning device 90 and the belt tensioning device 110 can be adjusted to control the slippage of the bandolier 20 and thus adjust the location at which the knife mechanism 50 cuts the bandolier to separate the pouches.
If desired, after generating an adjustment command, the controller 201 may be configured to enter a dwell or sleep mode with respect to further adjustments of the slippage of the bandolier 20 for some period of time or number of pouches 22 that are processed. With such a configuration, immediately after generating an adjustment command, the registration monitoring and control system 205 will not make or generate additional adjustment commands for some period of time. More specifically, after generating an adjustment command, the controller 201 is operative to make the corresponding adjustment to either or both of the paddle tensioning device 90 and the belt tensioning device 110 and allow the slippage of the bandolier 20 relative to the major knife hub 60 to reach a steady state before commanding another adjustment to the slippage. Such a dwell or sleep mode is desirable since the remote knife mechanism 10 may often process 1000-5000 pouches per minute. Without the dwell or sleep mode, the controller 201 may generate multiple adjustment commands before the impact of the first adjustment command is fully integrated into the bandolier cutting process.
Referring to
In an embodiment, the position of the registration mark 32 relative to the reference scale 212 is generated for each image that is obtained, which is one image for each trigger of the optical image sensor 216 by the trigger sensor 230.
More specifically, the optical image sensor 216 superimposes each captured image upon the linearly graduated reference scale 212. In an embodiment, each of the lines of the reference scale 212 may be given a numerical indicator or numerical output. As depicted, the lines of the reference scale 212 may be 1 millimeter apart and the numerical indicator or numerical output of each line may correspond to the number of millimeters from the left hand edge of the reference scale. A graduation line on the reference scale 212 that is aligned with the measurement edge of the registration mark 32 is identified and designated as the numerical output of the optical image sensor 216. In one example, the measurement edge may be the leading edge 32L of the registration mark 32. In another example, the measurement edge may be the trailing edge 32T of the registration mark 32.
The optical image sensor 216 is operative to generate a numerical output indicative of the alignment of the registration mark 32 with the reference scale 212. In an embodiment, the controller 201 may utilize the numerical output from the optical image sensor 216 as the alignment input used to determine whether the registration mark 32 is sufficiently aligned with the desired or target position. In another embodiment, the controller 201 may utilize an average of numerical output data from the optical image sensor 216 as the alignment input.
In one example, the average may be determined based upon the numerical output from a predetermined number of optical measurement cycles. In another example, the average may be determined by using a decaying averaging process. To generate a decaying average, the numerical output from the current optical measurement cycle or image is given a first percentage weighting and the decaying average of the prior optical measurement cycles is given a second percentage weighting. In an embodiment, the first percentage is substantially less than the second percentage so that the decaying average of the prior optical measurement cycles is given substantially more weight that the numerical output from the current optical measurement cycle. As an example of the first percentage being substantially less than the second percentage, the numerical value of the current image may be given a ten-percent weight and decaying average of the prior images may be given a ninety-percent weight. Other ratios may be used. The new decaying average is equal to the sum of the weighted numerical input from the new or current image and the weighted decaying average of the prior images. By utilizing such a decaying average, an average of the numerical output may be rapidly generated and the desired weighting for the current image and the prior decaying average may be set to optimize the pouch manufacturing process.
Once the alignment input is determined (e.g., using the actual numerical output or an average numerical output of the optical image sensor 216), the controller 201 may determine an alignment difference between the alignment input and the target position. If the alignment difference is within the operating range, the remote cutting mechanism 10 may continue to be operated without a change to the bandolier feeding process. If the alignment difference is outside the operating range, the controller 201 can generate an adjustment command to implement a suitable adjustment of the slippage of the bandolier 20 relative to the major knife hub 60 and thus adjust the registration mark-knife relationship. In this regard, the output signal of controller 201 maintains the pneumatic pressure delivered to pneumatic actuators 95 and 116 by proportional pressure regulators 300 and 310. Should adjustment be required, the adjustment command can modify the pressure maintained by one or both regulators 300 and 310. Such a modification may correspond to the adjustment amount stored within the controller 201.
Adjustment of the position of the registration mark 32 relative to the reference scale 212 can involve actuation of the actuators 95 and 116 of the paddle tensioning device 90 and belt tensioning device 110 independently or in conjunction with each other. These devices have opposite effects on registration mark position. Increasing the magnitude of the radial force of the paddle tensioning device 90 will move the registration mark rearward relative to the feed direction of the bandolier 20. Increasing the radial force of belt tensioning device 110 will cause forward movement of registration mark 32 relative to the feed direction of the bandolier 20. In some embodiments, the effect of the force of paddle tensioning device 90 has the potential to make corrections of a larger magnitude in terms of the dimension of the resultant adjustment. Consequently, depending on the severity of the correction determined necessary, a combination of adjustments of both the paddle tensioning device 90 and belt tensioning device 110 may be employed.
On recognition of either of the deviations described above, the controller 201 may generate an adjustment command to modify the signals to the proportional pressure regulators 300 and 310 so that they change the force applied by one or both actuators 95 and 116. For example, in the instance of the illustration of
Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned, or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.
This patent application claims the benefit of U.S. Patent Application No. 62/676,442, filed May 25, 2018, which is incorporated by reference.
Number | Date | Country | |
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62676442 | May 2018 | US |