U.S. patent application number 11/417702 was filed with the patent office on 2007-11-22 for apparatus and method for sensing a container positioned about a filling spout.
This patent application is currently assigned to Smurfit-Stone Container Enterprises, Inc.. Invention is credited to LaMont Stewart Pace, Christopher Stephan Wadium.
Application Number | 20070267095 11/417702 |
Document ID | / |
Family ID | 38668564 |
Filed Date | 2007-11-22 |
United States Patent
Application |
20070267095 |
Kind Code |
A1 |
Wadium; Christopher Stephan ;
et al. |
November 22, 2007 |
Apparatus and method for sensing a container positioned about a
filling spout
Abstract
An apparatus for filling at least one container defining an
opening is provided. The apparatus includes a filling spout in flow
communication with a source of filling material. The filling spout
is configured to enable the opening of the at least one container
to fit about the filling spout. At least two stationary sensor
assemblies are positioned about the filling spout. The at least two
stationary sensor assemblies are configured to detect whether a
container is positioned about the filling spout.
Inventors: |
Wadium; Christopher Stephan;
(Salt Lake City, UT) ; Pace; LaMont Stewart;
(Spanish Fork, UT) |
Correspondence
Address: |
PATRICK W. RASCHE;ARMSTRONG TEASDALE LLP
ONE METROPOLITAN SQUARE, SUITE 2600
ST. LOUIS
MO
63102-2740
US
|
Assignee: |
Smurfit-Stone Container
Enterprises, Inc.
|
Family ID: |
38668564 |
Appl. No.: |
11/417702 |
Filed: |
May 4, 2006 |
Current U.S.
Class: |
141/140 |
Current CPC
Class: |
B65B 1/18 20130101; B65B
51/225 20130101; B65B 57/02 20130101 |
Class at
Publication: |
141/140 |
International
Class: |
B65B 57/02 20060101
B65B057/02 |
Claims
1. An apparatus for filling at least one container, the at least
one container defining an opening, the apparatus comprising: a
filling spout in flow communication with a source of filling
material, the filling spout configured to enable the opening of the
at least one container to fit about the filling spout; and at least
two stationary sensor assemblies positioned about the filling
spout, the at least two stationary sensor assemblies configured to
detect whether a container is positioned about the filling
spout.
2. An apparatus in accordance with claim 1 wherein the at least two
stationary sensor assemblies are radially positioned about the
filling spout, each stationary sensor assembly of the at least two
stationary sensor assemblies comprising one of a laser sensing
component, an ultrasonic sensing component and a photoeye sensing
component.
3. An apparatus in accordance with claim 1 wherein each stationary
sensor assembly of the at least two sensor assemblies comprises a
laser sensing component configured to emit a light beam directed at
a spatial location on an outer surface of the filling spout.
4. An apparatus in accordance with claim 3 wherein the laser
sensing component is positioned within a housing.
5. An apparatus in accordance with claim 3 wherein the spatial
location is radially positioned about the outer surface of the
filling spout at about 120.degree. with respect to adjacent spatial
locations.
6. An apparatus in accordance with claim 5 wherein the spatial
location is substantially planar with adjacent spatial
locations.
7. An apparatus in accordance with claim 5 wherein a first spatial
location of a light beam emitted from a first stationary sensor
assembly of the at least two stationary sensor assemblies is
positioned at a first position along a length of the filling spout
and a second spatial location of a light beam emitted from a second
stationary sensor assembly of the at least two stationary sensor
assemblies is positioned at a second position along the length of
the filling spout different from the first position.
8. An apparatus in accordance with claim 3 wherein each stationary
sensor assembly is configured to measure a first distance between a
laser sensing component position and a corresponding spatial
position on the outer surface of the filling spout and a second
distance between the laser sensing component position and a spatial
location on an outer surface of the container positioned about the
filling spout.
9. An apparatus in accordance with claim 8 wherein each stationary
sensor assembly is positioned about the filing spout to measure a
substantially equal first distance.
10. An apparatus in accordance with claim 8 further comprising a
controller operatively coupled to each stationary sensor assembly
and in operational control communication with the filling spout,
wherein, upon each stationary sensor assembly detecting the second
distance, each stationary sensor assembly transmits a confirmation
signal to the controller indicating that a container is properly
positioned about the filling spout.
11. An apparatus in accordance with claim 8 wherein, upon at least
one stationary sensor assembly detecting the first distance, the at
least one stationary sensor assembly prevents a confirmation signal
from being transmitted to the controller indicating that a
container is properly positioned about the filling spout.
12. An apparatus in accordance with claim 8 wherein, upon at least
one stationary sensor assembly detecting the first distance, the at
least one stationary sensor assembly transmits a container
positioning error signal to the controller indicating that a
container is not properly positioned about the filling spout.
13. An apparatus in accordance with claim 1 further comprising a
support configured for receiving, in succession, a plurality of
containers, the support configured to maintain each successive
container in an upright, substantially erect orientation, with the
opening extending toward the apparatus.
14. An apparatus in accordance with claim 1 further comprising a
sealing apparatus including at least one sealing member configured
to be reciprocably moved between a sealing position in operable
engagement with the opening and a standoff position substantially
removed from the container.
15. A detection system for determining whether a container is
positioned about a filling spout of an apparatus for filling at
least one container, the filling spout in flow communication with a
source of filling material, the filling spout configured to enable
an opening defined by the container to fit about the filling spout,
the detection system comprising: at least two stationary sensor
assemblies positioned about the filling spout, each stationary
sensor assembly of the at least two stationary sensor assemblies
including a sensing component, the sensing component configured to
measure a first distance from a sensing component location to a
first spatial location on an outer surface of the filling spout and
a second distance from the sensing component location to a second
spatial location on an outer surface of the container positioned
about the filling spout.
16. A detection system in accordance with claim 15 wherein the
sensing component comprises one of a laser sensing component, an
ultrasonic sensing component and a photoeye sensing component.
17. A detection system in accordance with claim 15 wherein each
sensing component comprises a laser sensing component configured to
emit a light beam directed at the first spatial location on an
outer surface of the filling spout, the laser sensing component
electrically coupled to a controller configured to measure a first
distance from a laser sensing component location to the first
spatial location and a second distance from the laser sensing
component location to the second spatial location.
18. A detection system in accordance with claim 17 wherein the
first spatial location of the light beam emitted from each laser
sensing component is positioned radially about the outer surface of
the filling spout at about 120.degree. with respect to adjacent
first spatial locations.
19. A detection system in accordance with claim 17 wherein each
first spatial location is substantially planar with adjacent first
spatial locations.
20. A detection system in accordance with claim 17 wherein a first
spatial location of a light beam emitted from a first laser sensing
component is positioned at a first position along a length of the
filling spout and a first spatial location of a light beam emitted
from a second laser sensing component is positioned at a second
position along the length of the filling spout different from the
first position.
21. A detection system in accordance with claim 17 wherein each
laser sensing component is calibrated to measure a substantially
equal first distance.
22. A detection system in accordance with claim 17 wherein, upon
each laser sensing component detecting the second distance, each
laser sensing component transmits a confirmation signal to the
controller indicating that a container is properly positioned about
the filling spout.
23. A detection system in accordance with claim 17 wherein, upon at
least one laser sensing component detecting the first distance, the
at least one laser sensing component transmits a container
positioning error signal to the controller indicating that a
container is not properly positioned about the filling spout.
24. A method for filling at least one container, the at least one
container defining an opening, an apparatus being positioned along
a processing path, the method comprising: placing a container on a
support configured for receiving, in succession, a plurality of
containers, the support configured to maintain each successive
container in an orientation, with the opening extending toward the
apparatus; confirming that the container is positioned about a
filling spout of the apparatus, the filling spout in flow
communication with a source of filling material, the filling spout
configured to enable the opening of a container to fit about the
filling spout; and filling the container with filling material.
25. A method in accordance with claim 24 wherein confirming that
the container is positioned about a filling spout further
comprises: positioning at least two stationary sensor assemblies
with respect to the filling spout, each sensor assembly of the at
least two stationary sensor assemblies including a laser sensing
component configured to emit a light beam directed at a spatial
location on an outer surface of the filling spout; calibrating each
laser sensing component to measure a first distance from a sensing
component location to a spatial location on an outer surface of the
filling spout; detecting a second distance between each sensing
component location and a spatial location on an outer surface of
the container positioned about the filling spout; and confirming
that the second distance is less than the first distance.
26. A method in accordance with claim 25 wherein, upon each sensing
component detecting the second distance, each sensing component
transmitting a confirmation signal to a controller in operational
control communication with the filling spout indicating that a
container is properly positioned about the filling spout.
27. A method in accordance with claim 25 wherein, upon at least one
sensing component detecting the first distance, the at least one
sensing component transmitting a container positioning error signal
to a controller in operational control communication with the
filling spout indicating that a container is not properly
positioned about the filling spout.
28. A method in accordance with claim 27 further comprising
preventing flow of filling material through the filling spout until
each sensing component detects the second distance.
29. A method in accordance with claim 24 further comprising sealing
the container with a sealing apparatus while maintaining the
container in the upright position on the support.
30. A method in accordance with claim 24 further comprising
reciprocably pivoting and translating the filling spout between a
horizontal filling position and a retracted position, in which the
filling spout is tilted, filling nozzle upward, and moved backward
from the horizontal filling position.
31. A method for determining whether a container is positioned
about a filling spout of an apparatus for filling at least one
container, the filling spout in flow communication with a source of
filling material and configured to enable an opening defined by the
container to fit about the filling spout, the method comprising:
providing at least two stationary sensor assemblies positioned with
respect to the filling spout, each stationary sensing assembly of
the at least two stationary sensor assemblies including a sensing
component; calibrating each sensing component to measure a first
distance from a sensing component position to a position on an
outer surface of the filling spout; and measuring a second distance
between each sensing component position and a position on an outer
surface of the container positioned about the filling spout.
32. A method in accordance with claim 31 wherein, upon each sensing
component detecting the second distance less than the first
distance, each corresponding sensor assembly transmits a signal to
a controller in operational control communication with the filling
spout indicting that a container is positioned about the filling
spout.
33. A method in accordance with claim 31 wherein, upon at least one
sensing component detecting the second distance equal to the first
distance, a corresponding sensor assembly transmits a signal to a
controller in operational control communication with the filling
spout that a container is not positioned about the filling spout.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to an apparatus and method
for filling and/or sealing containers and, more particularly, to an
apparatus and method for accurately sensing whether a container has
been properly positioned about a filling spout of a filling
machine.
[0002] Conventional bag filling machines may include a mechanical
device or component for detecting whether a bag is positioned on a
filling tube. Some conventional filling machines include a wand or
a paddle that extends over a bag support within the filling
station. As the bag is positioned onto the filling tube, the bag
urges the wand or paddle to move and activate a relay component,
such as a contact or switch, to indicate that the bag is positioned
on the filling tube.
[0003] Other conventional filling machines include a clamp that
secures the bag to the filling tube. The clamp includes an air
supply flow path configured to allow air to flow through the clamp.
A corresponding hole is formed through a side wall of the filling
tube and in initial flow communication with the air supply flow
path. A supply of air indicates whether the bag is positioned on
the filling tube. For example, if a bag is positioned on the
filling tube, the hole formed through the side wall of the filling
tube is covered and flow communication between the air supply flow
path and the hole is prevented. An increase in pressure and/or a
decrease in air flow are detected to indicate that the bag is
positioned on the filling tube. If the bag does not cover the hole,
the supply of air flows into the filling tube to indicate that no
bag is positioned on the filling tube.
[0004] The conventional methods for determining whether the bag is
positioned on the filling tube require physical manipulation of the
bag. Further, the conventional methods may result in false
confirmation that the bag is positioned on the filling tube. For
example, false confirmations may result from placing the bag
adjacent to, but not about, the filling tube and moving the wand or
paddle. Similarly, placing the bag adjacent to, but not about, the
filling tube may also cover the hole to prevent flow communication
between the air supply flow path and the hole formed within the
filling tube. Such situations will result in a false confirmation
that the bag is positioned on the filling tube.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In one aspect, an apparatus is provided for filling at least
one container defining an opening. The apparatus includes a filling
spout in flow communication with a source of filling material. The
filling spout is configured to enable the opening of the at least
one container to fit about the filling spout. At least two
stationary sensor assemblies are positioned about the filling
spout. The at least two stationary sensor assemblies are configured
to detect whether a container is positioned about the filling
spout.
[0006] In another aspect, a detection system is provided for
determining whether a container is positioned about a filling spout
of an apparatus for filling at least one container. The filling
spout is in flow communication with a source of filling material
and configured to enable an opening defined by the container to fit
about the filling spout. The detection system includes at least two
stationary sensor assemblies positioned about the filling spout.
Each stationary sensor assembly of the at least two stationary
sensor assemblies includes a sensing component. The sensing
component is configured to measure a first distance from a sensing
component location to a first spatial location on an outer surface
of the filling spout and a second distance from the sensing
component location to a second spatial location on an outer surface
of the container positioned about the filling spout.
[0007] In another aspect, a method is provided for filling at least
one container defining an opening. An apparatus is positioned along
a processing path. The method includes placing a container on a
support configured for receiving, in succession, a plurality of
containers. The support is configured to maintain each successive
container in an orientation, with the opening extending toward the
apparatus. The method includes confirming that the container is
positioned about a filling spout of the apparatus. The filling
spout is in flow communication with a source of filling material
and configured to enable the opening of a container to fit about
the filling spout. The container is then filled with filling
material.
[0008] In another aspect, a method is provided for determining
whether a container is positioned about a filling spout of an
apparatus for filling at least one container. The filling spout is
in flow communication with a source of filling material and
configured to enable an opening defined by the container to fit
about the filling spout. The method includes providing at least two
stationary sensor assemblies positioned with respect to the filling
spout. Each stationary sensing assembly of the at least two
stationary sensor assemblies includes a sensing component. Each
sensing component is calibrated to measure a first distance from a
sensing component position to a position on an outer surface of the
filling spout. A second distance between each sensing component
position and a position on an outer surface of the container
positioned about the filling spout is then measured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a side elevation view of an exemplary filling and
sealing apparatus, in which the rear bag flaps are open;
[0010] FIG. 2 is a front end elevation view of the filling and
sealing apparatus shown in FIG. 1;
[0011] FIG. 3 is a fragmentary top plan view of the filling and
sealing apparatus shown in FIG. 1, in which the rear bag flaps are
shown in an open position and a closed position;
[0012] FIG. 4 is an enlarged fragmentary side elevation view of the
filling and sealing apparatus shown in FIG. 1, showing the filling
spout in an extended position and the rear bag flaps in the open
position;
[0013] FIG. 5 is an enlarged fragmentary side elevation view of the
filling and sealing apparatus shown in FIG. 1, showing the filling
spout in a retracted position and the rear bag flaps in the open
position;
[0014] FIG. 6 is a fragmentary side elevation view of the filling
and sealing apparatus shown in FIG. 1, showing the filling spout in
a retracted position and further showing a bag being sealed with
the rear bag flaps in the closed position;
[0015] FIG. 7 is a fragmentary front elevation view of an exemplary
filling and sealing apparatus;
[0016] FIG. 8 is a perspective view of the filling and sealing
apparatus shown in FIG. 7;
[0017] FIG. 9 is a fragmentary front elevation view of the filling
and sealing apparatus shown in FIG. 7 with a sealable valve bag
properly positioned about a filling spout;
[0018] FIG. 10 is a front elevation view of an exemplary sensor
assembly for the filling and sealing apparatus shown in FIG. 7;
[0019] FIG. 11 is a side elevation view of the exemplary sensor
assembly shown in FIG. 10 with a portion of a housing removed;
[0020] FIG. 12 is a front elevation view of an exemplary array of
sensor assemblies position about a filling spout of the filling and
sealing apparatus shown in FIG. 7; and
[0021] FIG. 13 is a front elevation view of an alternative
exemplary array of sensor assemblies position about a filling spout
of the filling and sealing apparatus shown in FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention provides an apparatus and method for
determining whether a container, such as a bag, including a
sealable or non-sealable valve bag, is properly positioned about a
filling spout of a filling apparatus. An array of sensor assemblies
is positioned about the filling spout to sense or detect whether
the container is properly positioned about the filling spout. Each
sensor assembly is configured to transmit a confirmation signal to
a controller in operational control communication with a filling
system of the apparatus indicating that a container is properly
positioned about the filling spout. Further, in one embodiment each
sensor assembly is configured to transmit a container positioning
error signal or no confirmation signal if the sensor assembly
detects that a container is not properly positioned about the
filling spout.
[0023] The present invention is described below in reference to its
application in connection with and operation of a filling apparatus
for filling sealable or non-sealable valve bags. However, it will
be apparent to those skilled in the art and guided by the teachings
herein provided that the present invention is likewise applicable
to any apparatus including a filling system, with or without a
sealing system, for use with any suitable bags including, without
limitation, multiple wall bags, such as valve bags fillable through
a generally horizontally positioned filling tube or spout and
open-mouth bags fillable through a generally vertically positioned
filling tube or spout. Further, the present invention may be
applied to systems for filling and/or sealing any suitable
container, including bags, boxes, cartons and/or display trays.
[0024] FIGS. 1-13 show an exemplary filling apparatus 10. Filling
apparatus 10 includes a filling tube or spout 12, which is
connected to a source of filling material (not shown). In one
embodiment, filling spout 12 is mounted to a frame assembly 13 of
apparatus 10. Frame assembly 13 provides sufficient support for the
various functional stationary and/or moving components of apparatus
10, as may be required or desired by the dictates of any particular
installation. Filling spout 12 includes a nozzle 14 configured for
insertion into an opening defined in a container, such as a valve
structure of a valve bag. Such valve bags are known in the art and
may include sealable valve bags such as disclosed in Kelley et al.,
U.S. Pat. No. 6,092,930. It is apparent to those skilled in the art
and guided by the teachings herein provided that other suitable
bags, as well as any suitable container, may be used with the
apparatus and method of the present invention. As shown in FIG. 1,
in one embodiment the bag is vertically supported by a support 16,
such as a bag chair. Support 16 may be a stationary support or
representative of a conveyor belt, roller table, indexing conveyor
structure or similar structure, such that support 16 is configured
to repeatably position individual bags in alignment with filling
spout 12.
[0025] In one embodiment, filling apparatus 10 includes a sealing
system having a sealer 18 with a heating element or ultrasonic horn
20 that is suitably mounted for reciprocable vertical movement into
and out of contact with an upper surface of a protruding valve
structure of a sealable valve bag. Suitable controls and operating
systems for actuating and generating heat and/or ultrasonic
vibrations are provided.
[0026] A pivotable sealer anvil 22 is pivotably mounted for
movement about an axis 23 (shown in FIG. 2) that passes more or
less perpendicularly relative to a longitudinal axis 24 (shown in
FIG. 1) of filling spout 12 with filling spout 12 in an extended
position, as shown in FIG. 1.
[0027] In an alternative embodiment, filling spout 12 is
horizontally and pivotally reciprocably mounted to frame assembly
13. Suitable linkage elements, such as linkage cylinder 25, front
linkage 26 and/or rear linkage 28, are provided for facilitating
enabling selective coordinated combined longitudinal/pivotal
reciprocation of filling spout 12. FIG. 3 is a fragmentary top plan
view of filling apparatus 10, in particular showing filling spout
12 and a mechanism for moving filling spout 12 in and out of the
valve structures of the bags. A flexible tube 30 is connected to an
end portion of filling spout 12 distal to nozzle 14. Depending upon
the material that is being put in the bags, flexible tube 30 may be
fabricated from any suitable leak and sift proof flexible material,
which may need to be a food-grade material, as requirements
dictate. As shown and described herein, flexible tube 30
accommodates the horizontal and pivoting movement of filling spout
12.
[0028] In alternative embodiments, flexible tube 30 is replaced
with a rigid tube having an end portion architecture configured to
permit an adjacent end of filling spout 12 to be pivotably moved
away from the rigid tube as filling spout 12 moves to a retracted
position. Suitable gasketing is used to provide an adequate seal at
the interface of the adjoining tube ends with filling spout 12 in
the extended position. Alternatively, any suitable connecting tube
constructions may be employed to permit or accommodate the pivoting
movement of filling spout 12.
[0029] In one embodiment, at least one bag side support 31 is
mounted to frame 13 for facilitating stabilizing the bag as the bag
is filled and/or sealed. As shown in FIGS. 1-3, bag side supports
31 have any suitable configuration such that the lateral spacing of
bag side support 31 is sufficiently close to the width of a bag as
the bag is being filled and sealed such that the bag is prevented
from shifting or moving to either side. Tipping of the bags may
lead to spillage and/or incomplete or inaccurate sealing of the bag
valves.
[0030] In one embodiment, apparatus 10 includes two rear bag flaps
50, which are located proximate the outer end of support 16. Rear
bag flaps 50 are mounted for reciprocating pivoting movement about
vertical axes 51. In this embodiment, each rear bag flap 50
includes an elongated rectangular paddle that is substantially
longer in a transverse direction than a vertical height. It is
apparent to those skilled in the art and guided by the teachings
herein provided that rear bag flaps 50 may have any suitable or
desired size and/or shape. Rear bag flaps 50 are moved between a
closed position and an open position, as shown in FIG. 3, by
corresponding rear bag flap actuators 52. In one embodiment, rear
bag flap actuators 52 are pneumatic or hydraulic cylinder and
piston arrangements, such as shown in FIG. 3. In alternative
embodiments, any suitable type of actuator that is controlled by a
suitably programmed control system may be used to move rear bag
flaps 50. When rear bag flaps 50 are in the closed position, rear
bag flaps 50 are either close to or in actual contact with the back
(the side opposite the valve tube) of a bag that is positioned on
support 16. This prevents a bag being filled and/or sealed from
being pushed away (e.g., by the rising sealer anvil prior to
sealing) or falling away from filling spout 12 or the sealer
mechanism. Rear bag flaps 50 thus facilitate ensuring a complete
and cleaner fill of the bags and a more positively positioned seal
of the bag valves.
[0031] While bag side supports 31 and rear bag flaps 50 are shown
in particular configurations, other configurations for bag side
supports 31 and/or rear bag flaps 50 may be used, as desired or
required by a particular installation.
[0032] In one embodiment, apparatus 10 includes a dust collecting
mechanism. A flexible shroud 56 is positioned to surround the end
portion of filling spout 12 distal to nozzle 14. Shroud 56 is
connected to a dust collection tube 58, which is connected to a
vacuum source (not shown). Shroud 56 has any suitable shape and/or
is made of any suitable flexible material generally known in the
art of bag filling apparatus. As is typically done, filling spout
12 enters into shroud 56 through a substantially sealed aperture
(not shown). In one embodiment wherein filling spout 12 is movable
(whether pivoting or longitudinally reciprocating), the dust
collection mechanism, including shroud 56 and dust collection tube
58, is substantially stationary, although those portions of shroud
58 that are directly coupled to filling spout 12 are sufficiently
flexible to accommodate the movements of filling spout 12 and
maintain a substantially sealed relationship to filling spout 12
throughout its movements.
[0033] FIG. 4 is a slightly enlarged view of filling apparatus 10,
showing filling spout 12 in an extended position. FIG. 5 shows
filling spout 12 in a retracted position. FIG. 6 is a fragmentary
side elevation of filling apparatus 10 of FIGS. 1-5, showing the
filling spout in the retracted position and further showing a bag
being sealed.
[0034] In operation, containers, such as valve bags, including
sealable or non-sealable valve bags, are placed at support 16 by
any suitable mechanism including, without limitation, a conveyor
belt, powered roller table, bag holding and/or indexing mechanism.
At support 16, the bag is positioned in an upright position with
the protruding valve structure pointing toward filling apparatus
10. Typically, in the process of raising the bags, a gripping
mechanism, as a known in the art, may squeeze the top of the bag
slightly, so as to pop open the end of the valve structure for
facilitating entry of nozzle 14 and/or filling spout 12. A pushing
device (not shown) may be employed for slightly moving the bag
toward nozzle 14 or, in an alternative embodiment, for simply
holding the bag in place while nozzle 14 is inserted into the valve
tube of a stationary bag.
[0035] In one embodiment, filling spout 12 is in an extended
position and is stationary when a valve bag 40 is placed on support
16. As described above, valve bag 40 may include a sealable or
non-sealable valve structure. Further, other suitable bags may be
filled with filling apparatus 10, as described herein. Valve bag 40
is then pushed onto nozzle 14 to assume the position shown in
phantom in FIG. 4, such as by a piston actuated pusher or bag
gripping device (not shown). In an alternative embodiment, nozzle
14 is inserted into the open valve tube of a stationary valve bag
40.
[0036] In either embodiment, the movement of nozzle 14 is the same
or similar. To extend nozzle 14, cylinder(s) 25 is/are actuated to
withdraw the pistons. Linkages 26 and 28 pivot forward and filling
spout 12 moves in a complex arc from the position shown in FIG. 5
to the position shown in FIG. 1, 3 or 4. Once pivoting of filling
spout 12 has been completed and valve 42 has been placed on nozzle
14 (or nozzle 14 inserted into valve structure 42), filling of
valve bag 40 can commence. Using a pump or other suitable means,
the material to fill valve bag 40 is supplied from a source, such
as a hopper 54 and flows in the direction indicated by arrow
55.
[0037] In one embodiment, linkage cylinder(s) 25 include a
hydraulic or pneumatic piston and cylinder assembly. In order to
accommodate the upward pivoting of filling spout 12, flexible tube
30 is collapsed and folded downward.
[0038] In the embodiments as described herein, suitable wiring,
tubing and control mechanisms (suitably programmed or coupled to
control actuators using known control techniques) are provided for
the selective and/or automated actuation of cylinder(s) 25 between
the retracted position and the extended position.
[0039] After filling is complete (based upon timing of flow,
volumetric measurement upstream of filling spout 12, or measurement
of weight at support 16, among other possible cut-off determination
techniques), filling spout 12 is generally pivoted backward from,
and nozzle 14 tilted upward with respect to, valve bag 40 such that
nozzle 14 is removed from valve structure 42. Apparatus 10 thus
returns to the configuration shown in FIG. 5.
[0040] Whether valve bag 40 is pushed onto a stationary nozzle 14
or nozzle 14 is pushed into a stationary valve bag 40, the relative
positions of the pivot points for the linkages and/or the lengths
of the linkages are selected such that during the pivoting movement
of filling spout 12 away from valve bag 40, the initial movement of
the nozzle 14 is to actually initially dip downwardly relative to
valve structure 42 before filling spout 12, as a whole, pivots
backward away from and tilts upward relative to valve bag 40. Such
a pivoting movement may be readily accomplished by one of ordinary
skill in the art having the present disclosure before them.
[0041] As shown in FIGS. 1-6, in one embodiment the linkages
coupled to filling spout 12 are coupled to the lower side of
filling spout 12 and are positioned generally below filling spout
12. The linkages are further configured such that filling spout 12
pivots up and away from valve bag 40 in the retracted position.
[0042] Referring to FIGS. 7-13, in one embodiment apparatus 10
includes a bag detection system 60 positioned with respect to
filling spout 12 for facilitating detecting whether a bag, such as
a valve bag 40, has been properly and accurately positioned about
filling spout 12 and/or nozzle 14 prior to beginning the bag
filling process.
[0043] In one embodiment, detection system 60 includes an array 62
of stationary sensor assemblies positioned about filling spout 12
and a controller 64 in operational communication with each sensor
assembly of array 62. FIG. 7 is a fragmentary end view of apparatus
10 including array 62 positioned with respect to filling spout 12.
FIG. 8 is a fragmentary perspective view of apparatus 10 including
array 62 positioned about filling spout 12. FIG. 9 is a fragmentary
end view of apparatus 10 including array 62 and a valve bag 40
properly and accurately positioned about filling spout 12. In one
embodiment, array 62 includes at least two sensor assemblies. As
shown in FIGS. 7-9, in this embodiment array 62 includes three
sensor assemblies 65, 66 and 67 positioned with respect to filling
spout 12 and/or nozzle 14 and configured to detect or sense whether
valve bag 40 is positioned about filling spout 12. In alternative
embodiments, array 62 includes any suitable number of sensor
assemblies, i.e., less than three sensor assemblies or more than
three sensor assemblies. Each sensor assembly 65, 66, 67 is mounted
to frame 13 using any suitable mounting component known to those
skilled in the art.
[0044] Referring further to FIGS. 10-13, sensor assemblies 65, 66,
67 are positioned about filling spout 12 and configured to detect
or sense whether valve bag 40 is properly and accurately positioned
about filling spout 12. In one embodiment, each sensor assembly 65,
66, 67 is contained within a housing 68 to protect the internal
sensor components from undesirable contact with and/or exposure to
dust or debris introduced during the bag filling process. In this
embodiment, housing 68 protects the sensor assembly components from
being covered with product or filling material being moved into the
bags on filling apparatus 10. Such product or filling material may
prevent or limit sensor assemblies 65, 66, 67 from working
properly. Further, in a particular embodiment, housing 68 is air
purged with a suitable amount of air to provide positive pressure
within housing 68 and prevent the product or filling material from
entering housing 68 as the purge air escapes from within housing
68. Purge air is supplied to each housing 68 through an efficient
circuit of hoses, as shown in FIGS. 7-9.
[0045] As shown in FIG. 10, in one embodiment housing 68 includes a
transparent panel 69 fabricated from a suitable transparent
material, such as a Lexan.RTM. material available from General
Electric Company located in Schenectady, N.Y. or any suitable
transparent or semi-transparent material, for facilitating
monitoring the operation of the sensor assembly components housed
within housing 68. In alternative embodiments, housing 68 may
include a solid, non-transparent panel in lieu of transparent panel
69.
[0046] Each sensor assembly 65, 66, 67 includes a laser sensing
component 70 positioned within housing 68 that emits a light beam
against an outer surface 72 of filling spout 12. As shown in FIG.
10, laser sensing component 70 emits one light beam 71. However, in
an alternative embodiment, laser sensing component 70 is configured
to emit a plurality of light beams directed at varying directional
angles against outer surface 72 of filling spout 12.
[0047] Housing 68 defines an aperture 73, as shown in FIG. 11,
through which light beam 71 travels. In alternative embodiments,
each sensor assembly 65, 66, 67 includes an ultrasonic sensing
component, a photoeye sensing component or any suitable sensing
component known in the art and guided by the teachings herein
provided in lieu of laser sensing component 70 for facilitating
detecting or sensing whether valve bag 40 is properly and
accurately positioned about filling spout 12. In this embodiment,
each sensor assembly 65, 66, 67 including corresponding housing 68
is coupled to frame 13 using a suitable mechanical component, such
as a bracket 74 shown in phantom lines in FIGS. 10 and 11. Further,
each sensor assembly 65, 66, 67 is in independent operational
communication with controller 64 via a suitable wire or cable 76,
as shown in FIGS. 12 and 13.
[0048] Referring further to FIGS. 12 and 13, laser sensing
component 70 of each sensor assembly 65, 66, 67 is positioned such
that laser sensing component 70 emits a light beam 71 directed at
outer surface 72 at a spatial location on outer surface 72. Each
spatial location is positioned with respect to adjacent spatial
locations of directed light beams emitted from corresponding sensor
assemblies. In a particular embodiment, laser sensing component 70
of each sensor assembly 65, 66, 67 is configured such that the
corresponding light beam emitted from laser sensing component 70 is
directed at a spatial location on outer surface 72 at a radial
distance of about 120.degree. with respect to a spatial location of
adjacent emitted light beams. Further, each sensor assembly 65, 66,
67 is positioned with respect to filling spout 12 and/or calibrated
to measure a first or initial distance between corresponding laser
sensing component 70 and outer surface 72. In a particular
embodiment, each sensor assembly 65, 66, 67 is positioned with
respect to filling spout 12 and/or calibrated such that a first or
initial distance between laser sensing component 70 of sensor
assembly 65 and outer surface 72 is substantially equal to a first
or initial distance between laser sensing component 70 of sensor
assembly 66 and outer surface 72 and a first or initial distance
between laser sensing component 70 of sensor assembly 67 and outer
surface 72, as shown in FIGS. 12 and 13. Each sensor assembly 65,
66, 67 is configured to measure a corresponding first or initial
distance between a location of laser sensing component 70 to the
corresponding spatial location on outer surface 72 of filling spout
12 where the emitted light beam contacts outer surface 72.
[0049] In an alternative embodiment, each sensor assembly 65, 66,
67 is positioned such that corresponding laser sensing component 70
emits a light beam directed at outer surface 72 at a spatial
location on outer surface 72, as desired, i.e., the corresponding
light beam emitted from laser sensing component 70 is directed at a
spatial location on outer surface 72 at a radial distance of less
than or greater than about 120.degree. with respect to a spatial
location of adjacent emitted light beams. In further alternative
embodiments including less than three sensors or more than three
sensors, the sensors are suitably positioned about filling spout 12
such that a corresponding laser sensing component emits a light
beam directed at outer surface 72 at a spatial location on outer
surface 72, as desired.
[0050] Further, in the embodiment shown in FIGS. 7-13, sensor
assemblies 65, 66, 67 are positioned such that corresponding laser
sensing component 70 emits a light beam directed at outer surface
72 at a spatial location on outer surface 72 substantially planar
to the spatial locations of the other emitted light beams, e.g.,
each spatial location of the emitted light beams is positioned
within a plane perpendicularly intersecting longitudinal axis 24 of
filling spout 12. In an alternative embodiment, at least one sensor
assembly of array 62 is positioned within a plane generally
parallel to a plane in which at least one other sensor assembly is
positioned. For example, in alternative embodiment, sensor assembly
65 is positioned with respect to a first location along a length of
filling spout 12 such that corresponding laser sensing component 70
emits a light beam directed at outer surface 72 at a spatial
location within a first plane intersecting filling spout 12 along
the length of filling spout 12. Additionally, sensor assembly 66
and/or sensor assembly 67 is positioned with respect to a second
location along the length of filling spout 12 different from the
first location such that corresponding laser sensing component 70
emits a light beam directed at outer surface 72 at a spatial
location within a second plane different from the first plane and
intersecting filling spout 12 along the length of filling spout
12.
[0051] Each sensor assembly 65, 66, 67 is configured for
facilitating determining whether valve bag 40 is properly
positioned about filling spout 12. Further, each sensor assembly
65, 66, 67 is configured to transmit a confirmation signal to
controller 64 indicating that valve bag 40 is properly positioned
about filling spout 12 or, in one embodiment, a bag positioning
error signal indicating that valve bag 40 is not properly
positioned about filling spout 12. When each sensor assembly 65,
66, 67 transmits a confirmation signal to controller 64 indicating
that valve bag 40 is properly positioned about filling spout 12,
controller activates a filling mechanism of apparatus 10 to begin
the bag filling process. In this embodiment, the bag filling
process will not begin until each sensor assembly 65, 66, 67
transmits a confirmation signal indicating that valve bag 40 is
properly positioned about filling spout 12.
[0052] With valve bag 40 properly positioned about filling spout
12, a portion of valve bag 40 interferes with the light beam
emitted from each laser sensing component 70 such that a second
distance shorter than the first distance is detected or sensed by
each sensor assembly 65, 66, 67 resulting in a status change. The
detected second distance represents a measurement between the
location of laser sensing component 70 and a corresponding location
on an outer surface 82 of valve bag 40 fit or positioned about
filling spout 12. Upon detecting or sensing that the measured
second distance is less than the measured first distance, each
sensor assembly 65, 66, 67 transmits a confirmation signal to
controller 64 indicating such and confirming that valve bag 40 is
properly and accurately positioned about filling spout 12. In one
embodiment, each laser sensing component 70 is configured to
accurately measure a distance of about 0.001 inch; thus, allowing
sensor assemblies 65, 66, 67 to accurately detect or sense valve
bag 40 positioned about filling spout 12.
[0053] In a situation wherein valve bag 40 is not properly
positioned about filing spout 12, at least one sensor assembly 65,
66, 67 does not sense or detect a second distance different than
the first distance or senses or detects a measured second distance
equal to the measured first distance resulting in no status change.
The sensing of a measured second distance equal to the measured
first distance or not sensing a second distance indicates that
valve bag 40 is not interfering with the light beam emitted from
corresponding laser sensing component 70 and, hence, valve bag 40
is not properly positioned about filling spout 12. If sensor
assembly 65, 66 and/or 67 does not sense a second distance or
senses the measured second distance equal to the measured first
distance, sensor assembly 65, 66 and/or 67 does not transmit a
confirmation signal and/or transmits a bag positioning error signal
to controller 64 indicating that valve bag 40 is not properly
positioned about filling spout 12. If controller 64 receives the
bag positioning error signal, controller 64 is configured to
prevent the initiation of the bag filling process or discontinue
the bag filling process until the bag positioning error is
resolved.
[0054] Upon confirmation that valve bag 40 is properly positioned
about filling spout 12, controller 64, in operational control
communication with apparatus 10 and/or filling spout 12, transmits
an initiation signal to activate the filling mechanism to fill
valve bag 40 with the filling material. In one embodiment, upon
detecting that the measured second distance is less than the
measured first distance, each sensor assembly 65, 66, 67 transmits
a confirmation signal to controller 64 indicating that a valve bag
40 is properly positioned about filling spout 12. However, when at
least one sensor assembly 65, 66, 67 detects that the measured
second distance is equal to the measured first distance (indicating
that valve bag 40 has not interfered with at least one emitted
light beam), sensor assembly 65, 66 and/or 67 detecting the
measured second distance does not transmit a confirmation signal to
controller 64. In a particular embodiment, sensor assembly 65, 66
and/or 67 detecting the measured second distance transmits a bag
positioning error signal to controller 64 indicating that a valve
bag 40 is not properly positioned about filling spout 12. Upon
receiving no confirmation signal from sensor assembly 65, 66 and/or
67 or receiving the transmitted bag positioning error signal from
sensor assembly 65, 66 and/or 67, controller 64 prevents a flow of
filling material through filling spout 12 until each sensor
assembly 65, 66, 67 confirms the detection of the measured second
distance less than the measured first distance.
[0055] In one embodiment, a method is provided for determining
whether a container, such as valve bag 40, is properly positioned
about filling spout 12 for filling at least one container with
filling material. Filling spout 12 is in flow communication with a
source of filling material and configured to enable the structure
of the container defining the opening to fit about filling spout
12. An array of sensor assemblies 62 is provided that includes a
plurality of stationary sensor assemblies radially positioned about
the filling spout. Each sensor assembly includes a sensing
component, such as a laser sensing component, that is calibrated to
measure a first distance from a sensing component position or
location to a spatial position or location on an outer surface of
the filling spout. Each sensor assembly is configured to measure a
second distance indicating that a container is positioned about
filling spout 12. The measured second distance is equal to a
distance between each sensing component position or location and a
corresponding position or location on an outer surface of the
container positioned about the filling spout.
[0056] Upon each sensing component detecting a measured second
distance less than the measured first distance, the corresponding
sensor assembly transmits a confirmation signal to a controller in
operational control communication with the filling mechanism
confirming that a container is positioned about the filling spout.
In response to the confirmation signal received from each sensor
assembly (indicating that the container is properly positioned
about the filling spout), the controller initiates activation of
the filling mechanism, which allows flow of the filling material
through the filling spout to fill the container properly positioned
about the filing spout. However, upon at least one sensing
component not sensing a second distance or at least one sensing
component sensing a measured second distance equal to the measured
first distance, the corresponding sensor assembly sensing no second
distance or sensing such measured second distance transmits a
container positioning error signal to the controller indicating
that a container is not properly positioned about the filling
spout. In response to at least one sensor assembly transmitting a
container positioning error signal (indicating that the container
is not properly positioned about the filling spout), the controller
prevents activation of or deactivates the filling mechanism to
prevent flow of the filling material through the filling spout.
Such flow of the filing material is prevented until each sensor
assembly transmits a confirmation signal to the controller
indicating that the container is properly positioned about the
filing spout.
[0057] After the container, such as valve bag 40, is filled with
the filling material, the container is sealed by a sealing
apparatus including sealer 18 and anvil 22. One possible mechanism
that may be used may be identical or similar to that employed in
Wadium et al., U.S. Pat. No. 5,244,532 (in which sealer 18 employs
an ultrasonic vibration horn 20), except that the anvil (instead of
the horn) is pivotably mounted. When a container is being filled,
or moved in or out of the filling station, anvil 22 is in the
position shown in solid lines in FIGS. 1, 4 and 5.
[0058] Once filling has been completed, anvil 22 is rotated
outwardly and upwardly, in the direction indicated by arrow 90 in
FIG. 5, to the position indicated in FIG. 6. Anvil 22 may be
pivotably mounted and propelled by suitable linkages and propulsion
mechanisms, similar to those employed moving filling spout 12, or
by other mechanisms understood by those of ordinary skill in the
art. More or less simultaneously, horn 20 is lowered, in the
direction of arrow 92, as shown in FIG. 5 (e.g., by a suitably
controlled piston and cylinder system or other mechanism), until
valve structure 42 is clamped between horn 20 and anvil 22, as
shown in FIG. 6. Ultrasonic vibrations and/or heat are then applied
for a sufficient period of time and to a sufficient degree to
activate the adhesive or sealable liner of valve structure 42.
[0059] Upon completion of the sealing step, horn 20 is raised and
anvil 22 is pivoted downwardly and away from the container. The
filled and sealed container is moved away from support 16 and
replaced by a successive empty container with the opening structure
ready to receive nozzle 14 or to be pushed onto nozzle 14.
[0060] The above-described apparatus and method for filling at
least one container, such as a valve bag, allows containers to be
accurately filled without spillage. More specifically, the
apparatus and method facilitate sensing or detecting whether a
container has been properly and accurately positioned about the
filling spout prior to initiating the container filling process. As
a result, containers are reliably and efficiently filled without
false confirmations that a container is properly positioned about
the filling spout.
[0061] Exemplary embodiments of an apparatus and method for filling
at least one container are described above in detail. The apparatus
and method are not limited to the specific embodiments described
herein, but rather, components of the apparatus and/or steps of the
method may be utilized independently and separately from other
components and/or steps described herein. Further, the described
apparatus components and/or method steps can also be defined in, or
used in combination with, other apparatus and/or methods, and are
not limited to practice with only the apparatus and method as
described herein.
[0062] While the invention has been described in terms of various
specific embodiments, those skilled in the art will recognize that
the invention can be practiced with modification within the spirit
and scope of the claims.
* * * * *