U.S. patent application number 14/523131 was filed with the patent office on 2015-04-30 for systems with film speed control and related devices, methods and computer program products.
The applicant listed for this patent is Tipper Tie, Inc.. Invention is credited to Brent Stallings, Thomas E. Whittlesey.
Application Number | 20150119217 14/523131 |
Document ID | / |
Family ID | 52996063 |
Filed Date | 2015-04-30 |
United States Patent
Application |
20150119217 |
Kind Code |
A1 |
Whittlesey; Thomas E. ; et
al. |
April 30, 2015 |
SYSTEMS WITH FILM SPEED CONTROL AND RELATED DEVICES, METHODS AND
COMPUTER PROGRAM PRODUCTS
Abstract
Methods, computer program products and apparatus for producing
encased products using a sensor assembly that generates a signal
associated with when additional sealed casing is needed based on a
tautness of the sealed film proximate the sensor assembly and
directs at least one servomotor to increase film-drive speed. The
increase may optionally be for a short time of less than one second
in response to a detected need for additional sealed casing to
thereby temporarily increase casing production speed and avoid a
need for an excess amount of tubular casing in a buffer.
Inventors: |
Whittlesey; Thomas E.;
(Durham, NC) ; Stallings; Brent; (Raleigh,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tipper Tie, Inc. |
Apex |
NC |
US |
|
|
Family ID: |
52996063 |
Appl. No.: |
14/523131 |
Filed: |
October 24, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61897940 |
Oct 31, 2013 |
|
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|
Current U.S.
Class: |
493/24 |
Current CPC
Class: |
B65B 57/12 20130101;
B65B 9/2014 20130101 |
Class at
Publication: |
493/24 |
International
Class: |
B65B 57/04 20060101
B65B057/04; B65B 51/26 20060101 B65B051/26; B65B 41/12 20060101
B65B041/12 |
Claims
1. A method for sealing flat roll stock into shaped casing for
encasing target products, comprising: forming tubular casing from
flat roll stock; automatically moving the tubular casing using a
film drive assembly with drive belts powered by at least one
servomotor; electronically generating a signal associated with when
additional sealed casing is needed using a sensor assembly residing
downstream of the film drive assembly based on a tautness of the
sealed film proximate the sensor assembly; then electronically
directing the at least one servomotor to increase film-drive
speed.
2. The method of claim 1, wherein the directing is carried out to
increase film drive speed for a short time of less than one second
in response to a generated signal to thereby temporarily increase
casing production speed and avoid a need for an excess amount of
tubular casing in a buffer.
3. The method of claim 1, wherein the short time is between about
0.1 ms and 5 ms.
4. The method of claim 1, wherein the increase in film-drive speed
is instantaneous with when the signal is generated, and wherein the
increase in film-drive speed is above an immediately prior average
film drive speed used for automatically moving the tubular
casing.
5. The method of claim 1, wherein the sensor assembly comprises a
follower that contacts an outer surface of the tubular casing,
wherein the electronically generating is carried out using the
follower, and wherein the follower pivots when the tubular casing
increases in tautness to cause the signal to be generated to
thereby indicate a need for additional sealed casing.
6. The method of claim 5, wherein the sensor assembly comprises an
elongate flag member that reciprocates over a proximity sensor
based on movement of the follower to generate the signal that
causes the electronically directed increase in film drive
speed.
7. The method of claim 1, further comprising monitoring for a
number of generated signals and generating an alert when there are
a plurality of signals within a defined time period to thereby
indicate a potential equipment malfunction and/or need for
adjustment.
8. The method of claim 1, further comprising monitoring for tubular
casing pulled upstream of the sensor assembly using a sensor or
encoder upstream of the sensor assembly in a direction closer to a
clipper, the clipper having a voider assembly for providing a
voiding operation on tubular packaging prior to clipping, wherein
the sensor or encoder monitors tubular casing pulled by it.
9. The method of claim 1, wherein the sensor or encoder is a
rotatable encoder that contacts an outer surface of the tubular
casing, the method further comprising allowing operation in an
intermittent or continuous run mode, wherein, in the intermittent
mode, the encoder is used to detect when tubular casing is being
pulled during filling and during voiding, encoder movement is not
used to direct the film drive system to supply a defined amount of
tubular casing but instead a defined amount of tubular casing is
supplied and input from the sensor assembly is deactivated or
overridden, and wherein, in the continuous mode, tubular casing is
supplied at a defined speed that is adjusted every defined number
of cycles based on an amount of tubular casing pulled as detected
by the encoder, and wherein film drive speed can be adjusted based
on input from the sensor assembly associated with tubular casing
tension and/or tautness, and wherein, during voiding, the sensor
assembly may be used and/or a defined length of tubular casing can
be supplied to accommodate for tubular casing used during
voiding.
10. The method of claim 1, wherein the sensor assembly has a
follower that resides between first and second longitudinally
spaced apart casing contact members held on a horn residing inside
a sealed tubular casing, wherein the electronically generating is
carried out using the follower, wherein the follower contacts an
outer surface of the tubular casing and pivots when the tubular
casing increases in tautness to directly or indirectly generate the
signal.
11. The method of claim 10, wherein the follower comprises a
downwardly curved shape and an upper surface thereof abuts an outer
surface of the tubular casing.
12. The method of claim 10, wherein the first and second casing
contact members are configured to have downwardly extending lobes
configured so that a lower surface of the contact members extends a
greater distance beyond an outer diameter of the horn than an
opposing upper surface.
13. An apparatus for packaging products using tubular casings
formed from flat roll stock for encasing products therein,
comprising: a horn; a forming collar residing about the horn, the
forming collar configured to cooperate with a roll of flat casing
material to force the flat casing material to take on a shape with
long edge portions of the casing material residing proximate each
other; a seal assembly held a longitudinal distance in front of the
forming collar in cooperating alignment with the horn; a film drive
system residing proximate the seal assembly in communication with
the horn, wherein the film drive system comprises at least one
servomotor; and a sensor assembly residing upstream of the film
drive system in communication with the film drive system, wherein
the sensor assembly is configured to generate a signal associated
with an increase in tautness of tubular casing associated with a
deficient amount of tubular casing relative to a tautness
associated with a sufficient amount of tubular casing to cause the
film drive system to increase film-drive speed.
14. The apparatus of claim 13, wherein the film drive speed is
increased for a short time of less than one second in response to a
respective generated signal to thereby temporarily increase
production speed and avoid a need for an excess amount of tubular
casing in a buffer.
15. The system of claim 13, wherein the short time is between about
0.1 ms and 5 ms.
16. The system of claim 13, wherein the increase in film-drive
speed is instantaneous with when the signal is generated, and
wherein the increase in film-drive speed is above an immediately
prior film drive speed.
17. The system of claim 13, wherein the sensor assembly comprises a
follower that contacts an outer surface of the tubular casing,
wherein the sensor assembly is configured to generate the signal
using the follower, and wherein the follower pivots when the
tubular casing increases in tautness to cause the signal to be
generated to indicate a need for additional sealed casing.
18. The system of claim 16, further comprising an elongate flag
member that is attached to the follower and reciprocates over a
proximity sensor based on movement of the follower to generate the
signal that causes the increase in film drive speed.
19. The system of claim 16, further comprising a controller that
monitors for a number of generated signals within at least one
defined time period to thereby indicate a potential equipment
malfunction or need for adjustment, and wherein the controller is
configured to generate an alert when there are a plurality of
detected signals with the at least one defined time period.
20. The system of claim 13, further comprising at least one sensor
or encoder upstream of the sensor assembly to monitor when casing
is pulled by it or them.
21. The system of claim 13, further comprising: a clipper with a
voider assembly residing upstream of the sensor assembly proximate
a discharge end of the horn; and at least one controller in
communication with the at least one servomotor of the film drive
assembly, the sensor assembly and the voider assembly, wherein the
at least one controller is configured to control timing of a
voiding operation to deactivate or override the sensor assembly
signal during a voiding operation and to direct the film drive
assembly to advance a fixed length of tubular casing during a
respective voiding operation.
22. The system of claim 13, further comprising at least one
controller configured to allow the film drive system to have
selectable intermittent or continuous run modes.
23. The system of claim 13, further comprising first and second
longitudinally spaced apart casing contact members held on the horn
residing inside a sealed tubular casing proximate the sensor
assembly, wherein the sensor assembly comprises a follower that
contacts an outer surface of the tubular casing and pivots when the
tubular casing increases in tautness to directly or indirectly
generate the signal.
24. The system of claim 23, wherein the follower comprises a
downwardly curved shape and an upper surface thereof abuts an outer
surface of the tubular casing.
25. The system of claim 23, wherein the first and second casing
contact members are configured to have downwardly extending lobes
configured so that a lower surface of the contact members extends a
greater distance beyond an outer diameter of the horn than an
opposing upper surface.
26. The system of claim 13, further comprising a bracket assembly
having laterally extending slots and longitudinally extending
slots, the sensor assembly held by the bracket assembly, wherein
the sensor assembly comprises a follower that resides on one side
of the bracket assembly attached to a flag member residing on an
opposite side of the bracket assembly with a shaft laterally
extending through a longitudinally extending slot, the bracket
assembly holding a sensor that generates a signal when the follower
is pushed down by an increase in tautness of film and pivots to
rotate the shaft to move the flag member over the sensor to thereby
generate the signal.
27. The system of claim 26, further comprising a clipper with a
voider assembly residing upstream of the sensor assembly proximate
a discharge end of the horn, wherein the bracket assembly also
holds an encoder at a level above the follower and at a distance
apart from the follower, closer to the clipper, wherein the encoder
resides above the horn and the follower resides below the horn.
28. A computer program product for operating a packaging apparatus
that can accommodate different casing materials and different horn
diameters to provide encased elongate products, the computer
program product comprising: a non-transitory computer readable
storage medium having computer readable program code embodied in
said medium, said computer-readable program code comprising:
computer readable program code configured to provide a plurality of
different predetermined operational modes for an apparatus that
releaseably mounts different diameter horns and respective
different size forming collars to supply different sized tubular
casings from flat roll stock; computer readable program code
configured to detect a signal from a sensor assembly residing
upstream of a film drive assembly having at least one servomotor
that powers the film drive assembly, wherein the signal is
associated with an increase in tautness of tubular casing from a
tautness associated with an average production film drive speed;
and computer readable program code configured to direct at least
one servomotor to increase film speed relative to an immediately
prior film speed.
29-32. (canceled)
33. A packaging system using flat roll stock sealed into shaped
casing for encasing target products, comprising: a horn; a forming
collar residing about the horn, the forming collar configured to
cooperate with a roll of flat casing material to force the flat
casing material into a defined shape; a casing sealer held a
longitudinal distance in front of the forming collar; a film drive
system residing proximate the casing sealer in communication with
the horn, wherein the film drive system comprises at least one
servomotor; a sensor assembly residing upstream of the film drive
system in communication with the film drive system, wherein the
sensor assembly is configured to generate a signal associated with
an increase in tautness of tubular casing associated with a
deficient amount of tubular casing relative to a tautness
associated with a sufficient amount of tubular casing to cause the
film drive system to increase film-drive speed; and at least one
processor configured to detect a respective generated signal from
the sensor assembly based on a tautness of the sealed film
proximate the sensor assembly then instantaneously direct the at
least one servomotor to increase drive speed, wherein, optionally,
the casing sealer is a heat-seal heater.
34. (canceled)
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S.
Provisional Application Ser. No. 61/897,940, filed Oct. 31, 2013,
the contents of which are hereby incorporated by reference as if
recited in full herein.
FIELD OF THE INVENTION
[0002] The present invention relates to apparatus, systems, methods
and computer program products that can seal film.
BACKGROUND OF THE INVENTION
[0003] Conventionally, in the production of consumer goods such as,
for example, pasty food or non-food products, such products are
pumped or stuffed into a casing in a manner that allows the casing
to fill with a desired amount of the product. One type of casing is
a heat-sealed tubular casing formed by sealing a thin sheet of
flexible material, typically elastomeric material, into a
cylindrical form. U.S. Pat. Nos. 5,085,036 and 5,203,760 describe
examples of automated, high-speed contact sealing apparatus forming
flat roll stock into tubular casings. The contents of these patents
are hereby incorporated by reference as if recited in full
herein.
[0004] It is known to configure the packaging machines to
accumulate "reserve" amounts of tubular casing in a buffer with
folds of tubular casing so that sufficient lengths of tubular
casing are available to be pulled, stuffed and clipped in a
continuous manner. U.S. Pat. No. 7,310,926, proposes methods that
measure lengths of film produced and lengths of film used to
attempt to control the amount of buffer, the contents of which are
hereby incorporated by reference as if recited in full herein.
Despite the foregoing, there remains a need for alternative control
systems, particularly control systems that can reduce or
substantially, if not totally, eliminate the requirement for
buffers of folded/compressed lengths of casing which may not be
appropriate for some casing materials and/or products.
SUMMARY OF EMBODIMENTS OF THE INVENTION
[0005] Some embodiments are directed to methods for sealing flat
roll stock into shaped casing for encasing target products. The
methods include: (a) forming tubular casing from flat roll stock;
(b) automatically moving the tubular casing under a sealer (e.g., a
heat-seal, tape seal or adhesive assembly) using a film drive
assembly with drive belts powered by at least one servomotor; (c)
electronically generating a signal associated with when additional
sealed casing is needed using a sensor assembly residing downstream
of the film drive assembly based on a tautness of the sealed film
proximate the sensor assembly; then (d) electronically directing
the at least one servomotor to increase film-drive speed.
[0006] The directing can be carried out to increase film drive
speed for a short time of less than one second in response to a
generated signal to thereby temporarily increase casing production
speed and avoid a need for an excess amount of tubular casing in a
buffer.
[0007] The short time can be between about 0.1 ms and 5 ms.
[0008] The increase in film-drive speed can be instantaneous with
when the signal is generated. The increase in film-drive speed can
be above an immediately prior average film drive speed used for
automatically moving the tubular casing.
[0009] The sensor assembly can include a follower that contacts an
outer surface of the tubular casing. The electronically generating
can be carried out using the follower. The follower can pivot when
the tubular casing increases in tautness to cause the signal to be
generated to thereby indicate a need for additional sealed
casing.
[0010] The sensor assembly can include an elongate flag member that
reciprocates over a proximity sensor based on movement of the
follower to generate the signal that causes the electronically
directed increase in film drive speed.
[0011] The method can include monitoring for a number of generated
signals and generating an alert when there are a plurality of
signals within a defined time period to thereby indicate a
potential equipment malfunction and/or need for adjustment.
[0012] The method can include monitoring for tubular casing pulled
upstream of the sensor assembly using a sensor or encoder upstream
of the sensor assembly in a direction closer to a clipper. The
clipper has a voider assembly for providing a voiding operation on
tubular packaging prior to clipping. The sensor or encoder monitors
tubular casing pulled by it (over, under or to a side thereof).
[0013] The sensor or encoder can include a rotatable encoder that
contacts an outer surface of the tubular casing and moves when
casing is pulled under over or the side thereof. The method can
include allowing operation in an intermittent or continuous run
mode. In the intermittent mode, the encoder can be used to detect
when tubular casing is being pulled during filling. During voiding,
encoder movement is not used to direct the film drive system to
supply a defined amount of tubular casing but a defined amount of
tubular casing can be supplied and input from the sensor assembly
can be deactivated or overridden. In the continuous mode, tubular
casing can be supplied at a defined speed that is adjusted every
defined number of cycles based on an amount of tubular casing used
as sensed by the encoder. Film drive speed can be adjusted based on
sensor assembly input associated with tubular casing tension and/or
tautness. During voiding, input from the sensor assembly may be
used and/or a defined length of tubular casing can be supplied to
accommodate for tubular casing used during voiding.
[0014] The sensor assembly can have a follower that resides between
first and second longitudinally spaced apart casing contact members
held on a horn residing inside a sealed tubular casing. The
electronically generating can be carried out using the follower,
wherein the follower contacts an outer surface of the tubular
casing and pivots when the tubular casing increases in tautness to
directly or indirectly generate the signal.
[0015] The follower can include downwardly curved shape and an
upper surface thereof can abut an outer surface of the tubular
casing.
[0016] The first and second casing contact members can be
configured to have downwardly extending lobes configured so that a
lower surface of the contact members extends a greater distance
beyond an outer diameter of the horn than an opposing upper
surface.
[0017] Other embodiments are directed to apparatus for packaging
products using tubular casings formed from flat roll stock for
encasing products therein. The apparatus include: (a) a horn; (b) a
forming collar residing about the horn, the forming collar
configured to cooperate with a roll of flat casing material to
force the flat casing material to take on a shape with long edge
portions of the casing material residing proximate each other; (c)
a casing sealer (e.g., a heat-seal heater, tape seal assembly or
adhesive assembly) held in a distance in front of the forming
collar; (d) a film drive system proximate the casing sealer,
wherein the film drive system comprises at least one servomotor;
and (e) a sensor assembly residing upstream of the film drive
system in communication with the film drive system. The sensor
assembly can be configured to generate a signal associated with an
increase in tautness of tubular casing associated with a deficient
amount of tubular casing relative to a tautness associated with a
sufficient amount of tubular casing to cause the film drive system
to increase film-drive speed.
[0018] The film drive speed can be increased for a short time of
less than one second in response to a respective generated signal
to thereby temporarily increase production speed and avoid a need
for an excess amount of tubular casing in a buffer.
[0019] The short time can be between about 0.1 ms and about 5
ms.
[0020] The increase in film-drive speed can be instantaneous with
when the signal is generated. The increase in film-drive speed is
such that the speed is above an immediately prior film drive
speed.
[0021] The sensor assembly can include a follower that contacts an
outer surface of the tubular casing. The sensor assembly can be
configured to generate the signal using the follower. The follower
can pivot when the tubular casing increases in tautness to cause
the signal to be generated to indicate a need for additional sealed
casing.
[0022] The system may include an elongate flag member that is
attached to the follower and reciprocates over a proximity sensor
based on movement of the follower to generate the signal that
causes the increase in film drive speed.
[0023] The system can include a controller that monitors for a
number of generated signals within at least one defined time period
to thereby indicate a potential equipment malfunction or need for
adjustment. The controller can be configured to generate an alert
when there are a plurality of detected signals with the at least
one defined time period.
[0024] The system can include at least one sensor or encoder
upstream of the sensor assembly to monitor when casing is pulled by
it or them.
[0025] The system can include a clipper with a voider assembly
residing upstream of the sensor assembly proximate a discharge end
of the horn and at least one controller in (direct or indirect)
communication with the at least one servomotor of the film drive
assembly, the sensor assembly and the voider assembly. The at least
one controller can be configured to control timing of a voiding
operation to deactivate or override the sensor assembly signal
during a voiding operation and to direct the film drive assembly to
advance a fixed length of tubular casing during a respective
voiding operation.
[0026] The system can include at least one controller configured to
allow the film drive system to have selectable intermittent or
continuous run modes.
[0027] The system can include first and second longitudinally
spaced apart casing contact members held on the horn residing
inside a sealed tubular casing proximate the sensor assembly. The
sensor assembly can include a follower that contacts an outer
surface of the tubular casing and pivots when the tubular casing
increases in tautness to directly or indirectly generate the
signal.
[0028] The follower can include a downwardly curved shape and an
upper surface thereof can abut an outer surface of the tubular
casing.
[0029] The first and second casing contact members can be
configured to have downwardly extending lobes configured so that a
lower surface of the contact members extends a greater distance
beyond an outer diameter of the horn than an opposing upper
surface.
[0030] The system can include a bracket assembly having laterally
extending slots and longitudinally extending slots. The sensor
assembly is held by the bracket assembly. The sensor assembly can
include a follower that resides on one side of the bracket assembly
attached to a flag member residing on an opposite side of the
bracket assembly with a shaft laterally extending through a
longitudinally extending slot. The bracket assembly can hold a
sensor that generates a signal when the follower is pushed down by
an increase in tautness of film and pivots to rotate the shaft to
move the flag member over the sensor to thereby generate the
signal.
[0031] The system can include a clipper with a voider assembly
residing upstream of the sensor assembly proximate a discharge end
of the horn. The bracket assembly can also hold an encoder at a
level above the follower and at a distance apart from the follower,
closer to the clipper. The encoder can reside above the horn and
the follower can reside below the horn.
[0032] Yet other embodiments are directed to computer program
products for operating a packaging apparatus that can accommodate
different casing materials and different horn diameters to provide
encased products. The computer program products can include a
non-transitory computer readable storage medium having computer
readable program code embodied in the medium. The computer-readable
program code can include: (a) computer readable program code
configured to provide a plurality of different predetermined
operational modes for an apparatus that releaseably mounts
different diameter horns and respective different size forming
collars to supply different sized tubular casings from flat roll
stock; (b) computer readable program code configured to detect a
signal from a sensor assembly residing upstream of a film drive
assembly having at least one servomotor that powers the film drive
assembly, wherein the signal is associated with an increase in
tautness of tubular casing from a tautness associated with an
average production film drive speed; and (c) computer readable
program code configured to direct at least one servomotor to
increase film speed relative to an immediately prior film
speed.
[0033] The computer readable program code to direct the at least on
servomotor to increase film drive speed can be configured to
increase the drive speed for a short time period to temporarily
increase casing production speed.
[0034] The short time period can be between about 0.1 ms and 5 ms,
and wherein the increase in film-drive speed is instantaneous with
when the signal is generated.
[0035] The sensor assembly can include a follower that contacts an
outer surface of the tubular casing, wherein the follower is
attached to a flag member. The follower pivots when the tubular
casing increases in tautness. The computer readable program code
that detects a signal from the sensor assembly can be configured to
detect the signal is based on when the elongate flag member moves
over a proximity sensor.
[0036] The computer program product can include computer readable
program code that counts generated signals within at least one
defined time period to thereby indicate a potential equipment
malfunction and/or need for equipment adjustment and/or to generate
an alert when there are a plurality of detected signals with the at
least one defined time period.
[0037] Still other embodiments are directed to packaging systems
using flat roll stock sealed into shaped casing for encasing target
products. The systems include a horn and a forming collar residing
about the horn. The forming collar is configured to cooperate with
a roll of flat casing material to force the flat casing material
into a defined shape. The system includes an adhesive sealer or
heat-seal sealer held a longitudinal distance in front of the
forming collar and a film drive system residing proximate the
adhesive sealer or heat-seal heater sealer in communication with
the horn. The film drive system includes at least one servomotor.
The system also includes a sensor assembly residing upstream of the
film drive system in communication with the film drive system. The
sensor assembly can be configured to generate a signal associated
with an increase in tautness of tubular casing associated with a
deficient amount of tubular casing relative to a tautness
associated with a sufficient amount of tubular casing to cause the
film drive system to increase film-drive speed. The system can also
include at least one processor configured to detect a respective
generated signal from the sensor assembly based on a tautness of
the sealed film proximate the sensor assembly then instantaneously
direct the at least one servomotor to increase drive speed.
[0038] It is noted that any one or more aspects or features
described with respect to one embodiment may be incorporated in a
different embodiment although not specifically described relative
thereto. That is, all embodiments and/or features of any embodiment
can be combined in any way and/or combination. Applicant reserves
the right to change any originally filed claim or file any new
claim accordingly, including the right to be able to amend any
originally filed claim to depend from and/or incorporate any
feature of any other claim although not originally claimed in that
manner. These and other objects and/or aspects of the present
invention are explained in detail in the specification set forth
below.
[0039] These and other objects and/or aspects of the present
invention are explained in detail in the specification set forth
below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] FIG. 1 is a front perspective view of a packaging machine
according to embodiments of the present invention.
[0041] FIG. 2 is a schematic illustration of a film speed control
system according to embodiments of the present invention.
[0042] FIG. 3A is a graph of an exemplary timing diagram according
to embodiments of the present invention.
[0043] FIG. 3B is a graph of another exemplary timing diagram
according to embodiments of the present invention.
[0044] FIG. 3C is a graph of an exemplary speed adjustment diagram
based on low supply signal input according to embodiments of the
present invention.
[0045] FIGS. 4A and 4B are schematic illustrations of a film speed
control system using a casing follower (e.g., dancer) according to
embodiments of the present invention.
[0046] FIG. 4B illustrates the follower or "dancer" moving in
response to tautness of casing relative to the position shown in
FIG. 4A.
[0047] FIG. 4C is a schematic illustration of another embodiment of
a film speed control circuit according to embodiments of the
present invention.
[0048] FIGS. 5A and 5B are front perspective views of a packaging
machine illustrating a normal position for an acceptable or
sufficient supply condition (FIG. 5A) and a "short" supply position
(FIG. 5B) according to embodiments of the present invention.
[0049] FIG. 6 is a front perspective view of a portion of a
packaging machine illustrating the product horn and casing sensor
assembly according to embodiments of the present invention.
[0050] FIG. 7A is an enlarged front perspective view of a casing
sensor assembly according to embodiments of the present
invention.
[0051] FIG. 7B is an enlarged rear perspective view of the casing
sensor assembly shown in FIG. 7A according to embodiments of the
present invention.
[0052] FIG. 8 is an enlarged side perspective view of an exemplary
film drive system according to embodiments of the present
invention.
[0053] FIG. 9 is a front view of a packaging machine illustrating
the servomotors in position relative to the film/casing drive
system according to embodiments of the present invention.
[0054] FIG. 10A is an enlarged front view of a casing sensor
assembly according to embodiments of the present invention.
[0055] FIG. 10B is an enlarged rear view of the casing sensor
assembly shown in FIG. 10A according to embodiments of the present
invention.
[0056] FIG. 10C is an enlarged rear view of the casing sensor
assembly shown in FIG. 10A, illustrating a "short supply" dancer
configuration and alert arm position according to embodiments of
the present invention.
[0057] FIG. 11 is a flow chart of operations that may be carried
out according to embodiments of the present invention.
[0058] FIG. 12 is a block diagram of a data processing system
according to embodiments of the present invention.
DETAILED DESCRIPTION
[0059] The present invention will now be described more fully
hereinafter with reference to the accompanying figures, in which
embodiments of the invention are shown. This invention may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Like
numbers refer to like elements throughout. In the figures, certain
layers, components or features may be exaggerated for clarity, and
broken lines illustrate optional features or operations unless
specified otherwise. The term "Fig." (whether in all capital
letters or not) is used interchangeably with the word "Figure" as
an abbreviation thereof in the specification and drawings. In
addition, the sequence of operations (or steps) is not limited to
the order presented in the claims unless specifically indicated
otherwise.
[0060] The term "concurrently" means that the operations are
carried out substantially simultaneously.
[0061] The term "about" means that the noted value can vary by
+/-20%.
[0062] It will be understood that when a feature, such as a layer,
region or substrate, is referred to as being "on" another feature
or element, it can be directly on the other element or intervening
elements may also be present. In contrast, when an element is
referred to as being "directly on" another feature or element,
there are no intervening elements present. It will also be
understood that, when a feature or element is referred to as being
"connected", "attached" or "coupled" to another feature or element,
it can be directly connected to the other element or intervening
elements may be present. In contrast, when a feature or element is
referred to as being "directly connected", "directly attached" or
"directly coupled" to another element, there are no intervening
elements present. The phrase "in communication with" refers to
direct and indirect communication. Although described or shown with
respect to one embodiment, the features so described or shown can
apply to other embodiments.
[0063] The term "circuit" refers to software embodiments or
embodiments combining software and hardware aspects, features
and/or components, including, for example, at least one processor
and software associated therewith embedded therein and/or
executable by and/or one or more Application Specific Integrated
Circuits (ASICs), for programmatically directing and/or performing
certain described actions, operations or method steps. The circuit
can reside in one location or multiple locations, it may be
integrated into one component or may be distributed, e.g., it may
reside entirely in or supported by a workstation or cabinet (e.g.,
HMI of a machine) or single computer, partially in one workstation,
cabinet, processor or computer, or totally in a remote location
away from a local computer, processor, workstation or cabinet. If
the latter, a local computer and/or processor can communicate over
a LAN, WAN and/or internet to transmit instructions and/or
data.
[0064] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a," "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," when used in this
specification, specify the presence of stated features, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, steps,
operations, elements, components, and/or groups thereof. As used
herein, the term "and/or" includes any and all combinations of one
or more of the associated listed items.
[0065] As used herein, phrases such as "between X and Y" and
"between about X and Y" should be interpreted to include X and Y.
As used herein, phrases such as "between about X and Y" mean
"between about X and about Y." As used herein, phrases such as
"from about X to Y" mean "from about X to about Y."
[0066] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and should not be
interpreted in an idealized or overly formal sense unless expressly
so defined herein.
[0067] The term "frame" means a generally skeletal structure used
to support one or more assemblies, modules and/or components. The
frame can be a floor mount frame. The term "automated" means that
operations can be carried out substantially without manual
assistance, typically using programmatically directed control
systems and electrical and/or mechanical devices. The term
"semi-automatic" means that operator input or assistance may be
used but that most operations are carried out automatically using
electromechanical devices and programmatically directed control
systems.
[0068] In the description of embodiments of the present invention
that follows, certain terms are employed to refer to the positional
relationship of certain structures relative to other structures. As
used herein, the term "front" or "forward" and derivatives thereof
refer to the general or primary direction that the filler or
product travels in a production line to form an encased product;
this term is intended to be synonymous with the term "downstream,"
which is often used in manufacturing or material flow environments
to indicate that certain material traveling or being acted upon is
farther along in that process than other material. Conversely, the
terms "rearward" and "upstream" and derivatives thereof refer to
the directions opposite, respectively, the forward and downstream
directions.
[0069] The term "servomotor" refers to a closed-loop servomechanism
with an electric motor that uses electronic feedback to control its
operation. The control can be automatic rather than manual. The
servomotor comprises the electric motor, at least one encoder, a
controller and driver. The servomotor components can be integrated
into a unitary package or distributed. The driver compares a
position command and the encoder position/speed information and
controls the drive current for the electric motor. The input to the
controller includes a signal, either analog or digital,
representing the position commanded for the output shaft of the
motor. The measured position of the output can be compared to a
command position and an external input to the controller. The
servomotor can be configured to measure both the position and the
speed of the output shaft. The speed of the motor is controlled
and, except potentially during short bursts or times, does not run
at full-speed during normal operation. The servomotor can operate
with a PID protocol to allow the servomotor to be brought to its
commanded position more quickly and more precisely. PID controllers
can make use of a speed signal. The servomotor encoder can comprise
an optical encoder, absolute or incremental, to determine position
at power-on. Incremental systems may combine their inherent ability
to measure intervals of rotation with a simple zero-position sensor
to set their position at start-up. The electric motor can be DC or
AC. In some embodiments, the servomotors can be an
electronically-commutated brushless motor. In some embodiments, the
servomotor can be an AC induction motors with variable frequency
drive that allows for control of its speed. In some embodiments,
the servomotor is a brushless AC motor with permanent magnet
fields.
[0070] The present invention is particularly suitable for producing
encased products that may also employ closure clips to seal
products held in the casings. The product may be a linked chain of
elongated pumped, flowed or extruded product held in a casing. The
casing can be any suitable casing (edible or inedible, natural or
synthetic) such as, but not limited to, collagen, cellulose,
plastic, elastomeric and/or polymeric casing. Typically, the casing
material comprises planar roll stock of film comprising elastomeric
and/or polymeric material. The elastomeric and/or polymeric sheet
material is a relatively thin sheet (or film) of roll-stock that
can be formed in situ into a continuous length of heat-sealed
and/or otherwise joined or seamed tubular casing. Embodiments of
the invention are configured to seal laminated or multi-layer
films. The multi-layer films can comprise different materials,
typically one material as a first layer and a second material as an
overlying second layer. The different materials can be laminated or
one layer can be a coating such as a metalized spray coating. The
laminated or multi-layer films can include "foil film", metalized
polymeric and/or elastomeric films, such as aluminized plastic
and/or aluminized polymeric films. In some embodiments, the films
can comprise heat-shrink films.
[0071] The term "film" means the material is thin. The thickness is
typically under about 0.5 mm, such as in a range of between about
0.02 mm to about 0.3 mm, typically between about 0.03 mm to about
0.13 mm. In some embodiments, the film can have a thickness that is
about 0.03 mm, about 0.04 mm, about 0.05 mm, about 0.06 mm, about
0.07 mm, 0.08 mm, about 0.09 mm, about 0.10 mm, about 0.11 mm,
about 0.12 mm, about 0.13 mm, about 0.14 mm, about 0.15 mm, about
0.16 mm, about 0.17 mm, about 0.18 mm, about 0.19 mm, about 0.20
mm, about 0.25 mm, about 0.30 mm and the like. However, the casing
can have other thicknesses.
[0072] The forming can be carried out substantially automatically
and intermittently and/or continuously over a desired interval,
typically between at least about 45-60 minutes, depending on the
size of the length of the roll stock, pump speed and film drive
speed, for example. The sealing can be performed using a heat seal.
The seal can seal a seam formed by joining two outer long sides of
the casing/film. The seam can be a flat, fin, or other overlapping
and/or abutting joint configuration.
[0073] The encased elongated or tubular product can be an elongated
food product. Exemplary meat products include, but are not limited
to, strands of meat (that may comprise pepperoni, poultry, and/or
beef or other desired meat), and processed meat products including
whole or partial meat mixtures, including sausages, hotdogs, and
the like. Other embodiments of the present invention may be
directed to seal other types of food (such as cheese) or other
product in casing materials. Examples of other products include
pasty products such as caulk or powders such as granular materials
including grain, sugar, sand and the like or other flowable
materials including wet pet food (similar to that held
conventionally in cans) or other powder, granular, solid,
semi-solid or gelatinous materials including explosives. Thus,
embodiments of the invention can be used for packaging target
products for any industry including food, aquaculture, agriculture,
environmental, building or home maintenance supplies, chemical,
explosives, or other applications.
[0074] The term "instantaneous" means that the increase in speed
occurs essentially at the same time as a sensor signal associated
with a low tubular casing is generated and/or detected, typically
within about 0.1 second, typically within about 0.01 seconds or
less thereof.
[0075] Turning now to FIG. 1, an exemplary packaging apparatus 10
configured to form tubular casings is shown. The apparatus 10
includes a (heat-seal) horn 20, a forming collar 30, a heat-seal
assembly 40 (also called a "heat-seal heater"), a casing drive
assembly 45 (which will be referred to hereafter as a "film" drive
assembly), a casing sensor assembly 100 and optionally at least one
pre-heater 50.
[0076] To be clear, the term "film drive assembly" refers to drive
assemblies that drive any casing material on the apparatus, not
just film.
[0077] While the figures illustrate a heat-seal heater 40 for
forming the seal on the casing, it is also contemplated that other
sealing assemblies can be used rather than or with the heat-seal
heaters, including, for example, adhesive (heated) or tape seal
systems as is known to those of skill in the art. Also, while shown
with respect to a single clipper system, the packaging system can
be a multi-clipper system. See, e.g., U.S. Pat. No. 8,006,463, the
contents of which are hereby incorporated by reference as if
recited in full herein.
[0078] The system 10 typically also includes a clipper 75 and
voiders V that cooperate with the clippers to void filling in a
tubular package to allow the clipper 75 to apply one or more clips
to a filled package to seal a respective package.
[0079] FIG. 2 illustrates that the apparatus 10 can include or be
in communication with a controller 500 that is in communication
with the casing sensor assembly 100 and at least one servomotor
200. The servomotor(s) 200 is in communication with the film drive
assembly 45 to be able to control casing/film drive speed. The film
drive assembly 45 and/or the controller 500 can be in communication
with the sealer 40 (e.g., heat-seal heater, tape seal assembly or
adhesive seal assembly).
[0080] The apparatus 10, using the sensor assembly 100 and at least
one servomotor 200 (FIGS. 2, 8 and 9) in communication with the
film drive assembly 45, can be configured to operate without
requiring a large buffer B (FIG. 5A) of sealed tubular casing F. In
some embodiments, no buffer B is required. In some embodiments, a
limited amount of buffer B is used.
[0081] In some embodiments, the system 10 can be configured to
produce a small excess amount of tubular sealed casing at the
beginning of each roll of flat stock, e.g., between about 1-2
inches. In other embodiments, the system 10 can be configured to
only produce what is used for each clip cycle or slightly less and
the sensor assembly 100 can be used to determine when the tubular
casing F is taut to have the system 10 produce additional tubular
casing instantaneously when needed.
[0082] The system 10 can have a normal operating speed that can be
sped up in situ automatically based on the sensor assembly 100
detecting when an amount of tubular film is short of a desired
amount based on a tautness of the tubular casing proximate the
sensor assembly 100. The sensor assembly 100 can be configured to
contact the tubular casing F between the film drive assembly 40 and
the discharge end of the horn 20d and generate a signal that
identifies when there is a low or insufficient amount of tubular
casing.
[0083] In some particular embodiments, the system 10 can operate
without requiring a buffer B of tubular film F. In this embodiment,
the tubular film F can be supplied so that it has only a sufficient
length or slightly under a sufficient length needed for voiding and
clipping to form a particular length of product, but not a length
that is in excess of the amount needed for a particular length of
product.
[0084] The system 10 can be configured to inhibit or disallow undue
amounts of wrinkle or fold formation (e.g., "crinkling") in the
supplied formed tubular casing. This tight control can avoid
creases, microfissures, cracks and/or microfractures in fragile
casings such as laminated aluminum films.
[0085] The film speed and other operational parameters can be
selected at set-up. The machine 10 can supply tubular casing F at a
defined speed range that can be determined or identified at set-up.
This speed can be controlled to produce sealed tubular casing F in
respective lengths corresponding to amounts to be successively
filled and clipped, but there can be variation during production
depending on density of the product, speed of the pump, casing
type, product length and speed of the film drive and heat-seal
assemblies and the like.
[0086] As shown in FIG. 2, the system 10 can include a controller
500 that communicates with the film sensor assembly 100 and a
servomotor 200 to be able to increase the speed of the film drive
assembly 45 from a preset or normal drive speed for short times,
such as between about 0.1 ms to about 5 ms, in response to each
identified "low" film signal input from the sensor assembly 100.
The short time may be under 1 second, such as, for example, between
about 0.1 ms to about 5 ms, including about 0.2 ms, about 0.3 ms,
about 0.4 ms, about 0.5 ms, about 0.6 ms, about 0.7 ms, about 0.8
ms, about 0.9 ms, about 1 ms, about 1.5 ms, about 2 ms, about 2.5
ms, about 3 ms, about 3.5 ms, about 4 ms, about 4.5 ms and about 5
ms.
[0087] FIG. 3A illustrates an exemplary timing graph of sensor low
film input with a corresponding servomotor increase speed mode. The
increase speed mode can be essentially instantaneous, if not
instantaneous, response to a low film signal and can be operated
with relatively brief "on" periods corresponding to the low film
signal then "off" periods for normal speed. Thus, as shown in FIG.
3A, in some embodiments, the system 10 can have a normal (average)
operating film drive speed S.sub.N per product type and/or product
size that can be increased S.sub.I in situ automatically based on
the casing sensor assembly 100 responding to (e.g., generating and
detecting) an increase in tension associated with the tubular
casing supply being insufficient or short.
[0088] In some embodiments, the low supply signal can be used to
automatically adjust average operating film speed S.sub.N,
particularly where successive low supply signals are generated
within a defined (e.g., short) time frame. In some embodiments, the
signal can generate a change in speed that has an instantaneous
"burst" or greatly increased first speed for a short time period
S.sub.I, followed by reduced speed from the first increased speed
but that is a small increase above a prior running average film
drive speed S.sub.Ni as shown in FIG. 3C, for example.
[0089] The duration of the increase and/or the increase in speed
itself can be predefined and can vary by product type, size, casing
material, filling speed and the like. The duration can be for a
short time interval and/or may be carried out to increase average
film drive speed.
[0090] The increase in speed S.sub.I of the film drive assembly 45
can be any suitable increase. In some particular embodiments, it is
contemplated that the increase may be between about 1%-200% more
than S.sub.N. S.sub.I may be, for example, about 1%, about 2%,
about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about
9%, about 10%, about 15%, about 20%, about 30%, about 40%, about
50% or more such as about 100%, about 150% or about 200% above
S.sub.N. The increase in speed can be for a short time period. The
increase in speed can be to increase the average film drive speed.
The latter may be for normal operation or used when successive low
supply signals may be detected/generated within a defined time
interval.
[0091] The short time interval for increase in speed can be any
suitable interval, typically under about 1 second. In some
embodiments, the short time interval of increased speed may be
between about 0.1 ms to about 5 ms, for example.
[0092] The duration of the increase in film speed can vary or be
the same over a roll of film stock. The amount of increase in film
speed can vary or be the same over a roll of film stock. For
example, if two low signals are received within a short amount of
time, the increase in film speed may be increased from the first
increase in speed and/or the duration may increase from the first
increase speed period. Repeat low supply signals may also be used
to indicate a need (or cause an adjustment of speed) for average
film speed operation.
[0093] FIG. 3A illustrates that the sensor assembly 100 can
generate a signal indicating film/casing supply at the sensor
assembly 100 is low at t.sub.1, t.sub.2, and t.sub.3, for example,
and, in response to this signal, an instantaneous short increase in
film drive speed associated with servomotor output occurs.
[0094] FIG. 3B illustrates that, in some embodiments, the apparatus
10 can operate so that film drive speed is adjusted based on voider
operation V. The pump P may also be slowed or stopped during a
voiding operation. The sensor assembly 100 may be disregarded or
inactivated during a voiding operation.
[0095] FIG. 4A illustrates an example of the sensor assembly 100 at
a normal film speed and sufficient supply while FIG. 4B illustrates
the sensor assembly 100 sending a signal that there is insufficient
supply and/or a need for increased film speed. The sensor assembly
100 can include a casing follower (also called a "dancer") 105. The
follower 105 resides external of the tubular casing downstream of
the film drive system 45. FIG. 4B illustrates the follower 105
moved by the casing F contacting the follower 105 when the casing F
is taut.
[0096] The sensor assembly 100 can be configured to generate a
signal to the control circuit 100c such as to the controller 500
and/or directly to the servomotor 200 to increase film drive speed
because more casing/film is needed.
[0097] FIG. 4B illustrates that the "low" supply and/or tubular
casing F "tension" signal can be based on a movement of the
follower 105 in response to a tautness of the film at the follower
105 rather than an actual measurement of tension of the tubular
casing F.
[0098] The follower 105 can reside to the side or above the casing
F and horn 20 rather than below the casing F and horn 20 as
shown.
[0099] FIG. 4C illustrates another embodiment where the sensor 130'
can be placed on a casing contact member 122 that resides inside
and can contact the casing F. The sensor 130' can include a
pressure or force sensor such as a piezoelectric sensor, a
piezoresistive pressure sensor, a monocrystalline silicon pressure
sensor, a thin film pressure sensor, a capacitive or resistive
transducer and the like. The sensor 130' can include a single
component or a plurality of (e.g., two closely spaced) cooperating
components. If the latter, one or both of the components can
stretch, move apart or elongate when tautness of the tubular casing
F thereon increases (typically above a defined level). The sensor
130' can contact the tubular casing F and can generate a signal
that can be sent to the controller 500 (and/or directly to the
servomotor 200) to increase film drive speed S.sub.I. The sensor
130' can be wireless or hard-wired to a circuit 100c for servomotor
control. If the latter, the wiring can be directed along the horn
20 toward the forming collar 30 to the circuit 100c connection.
[0100] The system 10 can be configured to generate an alert or to
stop filling and casing/film production if too many sensor assembly
low supply signals are generated within a defined time period,
e.g., 2 or more in under about 30 seconds to about 1 minute, or
more than a plurality e.g., more than 3 in 5 minutes, for example,
as such can indicate a problem with the belt drive, for
example.
[0101] FIGS. 4A and 4B schematically illustrate that the sensor
assembly 100 can include a casing (e.g., film) follower 105 that
can move up and down with respect to looser (FIG. 4A) or tighter
(FIG. 4B) amounts of tubular casing F (e.g., film with increased
tension) residing proximate thereto. A sensor 130 can detect a
change in position of a flag member 125 based on movement of the
follower 105. The controller 500 can detect the low supply signal
130s (FIG. 4B) from the sensor 130 and direct the servomotor 200 to
increase speed. The sensor 130 can be any suitable sensor that can
generate a signal to indicate when a short supply condition exists
to cause the servomotor to increase speed. The sensor signal can be
generated using contact or non-contact sensor signal. The sensor
130 can include one or more of a proximity switch (such as a
Hall-Effect sensor), an electrical or optical encoder, a pressure
or force sensor, a break in a light (e.g., laser) signal between a
laser or light transmitter and a receiver, an acoustic sensor or
other suitable signal generating device.
[0102] The follower 105 is shown as indirectly generating the "low
film" or "increase speed" signal using the flag member 125.
However, it is contemplated that in some embodiments, the movement
of the follower 105 can directly trigger the signal based on
detection of the movement of the follower itself without requiring
the flag member. Thus, the system 10 can be configured to
electronically detect movement of the follower based on increases
in tautness to directly generate the signal using an optical or
other encoder or sensor or camera, for example.
[0103] As shown in FIGS. 4A, 4B, and 6, the sensor assembly 100 can
cooperate with at least one casing contact member 122, shown as
first and second longitudinally spaced apart casing contact members
122.sub.1, 122.sub.2 on the product horn 20. The members 122 are
shown as disks or collars but can have other configurations. The
members 122 can have the same or different configurations. The
casing contact members 122 can encase the horn 20 as shown or
reside over only about a portion of the outer diameter of the horn,
e.g., circumferentially extend between about 90-180 degrees, for
example. As shown, the follower 105 can reside proximate the casing
contact member 122 outside the casing F. Where the first and second
longitudinally spaced apart casing contact members 122.sub.1,
122.sub.2 are used, the follower 105 resides between them,
typically longitudinally centered, but the follower 105 may reside
closer to one than another.
[0104] In some embodiments, the casing contact members 122 may be
substantially flush with the outer diameter of the horn at the
upper surface of the horn 20u and may be configured with lobes 122l
that extend a distance beyond the diameter of the horn at a bottom
surface of the horn 20b as shown in FIG. 9.
[0105] Although shown as two casing contact members 122, in some
embodiments, a single member may be used.
[0106] The outer diameter of the member 122 can be configured to
define an outer diameter of the target filled tubular product,
e.g., where a four inch tubular product is produced, the casing
contact members 122 have an outer diameter of about 4 inches
(typically just above this value). The casing contact members 122
may project a distance below (or above if the follower 105 resides
above the horn) an outer diameter of the horn 20 or where
integrated into the horn, relative to a diameter of the horn
upstream and downstream thereof.
[0107] Where first and second casing contact members 122.sub.1,
122.sub.2 are used, they can be spaced apart a defined distance.
This spacing and the distance "D" from the discharge end of the
horn 20d (FIG. 6) can be adjusted or vary depending on the product,
casing, pump speed, film speed, size of the horn and the like. The
members 122 can be integral to the horn 20 or can be separate
components attached to the horn 20. The casing contact members 122
can have an outer surface that has reduced friction, e.g., may have
a lubricious coating or material to facilitate the tubular casing F
sliding thereover.
[0108] FIGS. 5A and 5B illustrate, respectively, the packaging
system 10 with a "normal" suitable length casing supply and "low"
casing supply that can be detected by the sensor assembly 100. In
some embodiments, the system 10 can be configured to include a
small excess amount of tubular casing or buffer B that allows a
loose configuration or successive fold. The buffer B can reside
between the film drive assembly 45 and the sensor assembly 100
(FIG. 5A). The film folds F in the buffer B can be provided by the
machine 10 so that tubular casing F can be sealed to have a small
reserve at initiation of a packing/filling cycle (FIG. 5A) and/or
at other times during the packaging to assure that there is
sufficient casing/film sealed F for filling. FIG. 5B illustrates
that the buffer B can be depleted but the sensor assembly 100 can
identify this situation and generate a signal to cause the film
drive assembly 45 to immediately increase film-drive speed for a
short duration. The buffer B and/or sensor assembly 100 can inhibit
the machine 10 from running out of sealed film F while successive
products are stuffed.
[0109] With some casings, the machine 10 can run with a generous
amount of buffer B. However, some types of casing/film are
susceptible to damage if the casing/film gets bunched up and
creased. The sensor assembly 100 can allow the packaging machine to
have an intermittent operation to avoid excess or any bunching of
susceptible films.
[0110] In some embodiments, the system 10 can be configured to
selectively operate in either a continuous mode or an intermittent
mode.
[0111] In some embodiments, the system 10 may optionally include an
encoder or sensor 145 residing proximate the sensor assembly 100.
The encoder or other sensor 145 can help set an appropriate average
drive speed of the film drive system 45 during filling. That is,
the encoder or sensor 145 can detect when tubular casing F is
supplied (e.g., pulled thereunder) by the drive assembly 45 and
cooperating heat seal assembly 40.
[0112] In some embodiments, the encoder or sensor 145, where used,
can reside upstream of the heat-seal assembly 40 and typically also
upstream of the casing sensor assembly 100. The encoder or sensor
145 can be used to detect when tubular casing F is being pulled
forward during a respective filling process.
[0113] As is well known to those of skill in the art, during
voiding, the tubular casing F can be pulled abruptly forward (e.g.,
jerked rapidly upstream by voiders V) in front of the discharge end
of the horn 20d when the voiders V close and separate. This action
can impair or destroy the heat-seal on the tubular casing if
sufficient force is applied to the film upstream, against the pull
direction of the voiders. In some embodiments, during voiding, the
system 10 can be synchronized to disregard or inactivate the sensor
assembly 100 and/or encoder or sensor 145 and instead provide a
defined length/amount of casing from the film drive assembly 45 to
accommodate for the amount of casing used during voiding, rather
than using input from the encoder or sensor 145. The amount or
length of casing supplied during voiding can vary depending on the
casing material, the horn size, pump speed, film drive assembly
speed and the product. Although the encoder or sensor 145 is shown
in FIGS. 1, 7A and 7B as a rotating contact-encoder, other sensors
or contact encoders or non-contact sensors or encoders of any
variety may also be used.
[0114] The voiding operation of the voiders V can be detected using
a sensor such as a proximity or position sensor of any type and/or
based on input from a controller which may be controller 500 (FIG.
2) and/or controller for the HMI (FIG. 1) that directs the voiding
operation.
[0115] In a continuous mode, the tubular casing F can be supplied
at a set speed that can be automatically adjusted every defined "x"
number of cycles based on the amount of casing used as detected by
the encoder or sensor 145 and/or based on a number of
"tautness-induced" insufficient supply (flag) signals being
indicated by the sensor assembly 100.
[0116] FIGS. 7A and 7B illustrate an exemplary embodiment of a
sensor assembly 100. As shown, the assembly 100 includes the
follower 105 and the follower arm 108. The follower arm 108 is
attached to a shaft 108s that extends orthogonal to the arm 108.
The shaft 108 is fixedly attached to a hub 109. The hub 109 can be
held in a bearing flange 129 to facilitate movement (rotation back
and forth) of the proximity flag 125 over the sensor 130. When the
follower 105 moves down, the arm 108 pivots about the shaft axis
108s at pivot 108p, causing a proximity flag member 125 to move
over a sensor 130, shown as a proximity switch 130p. The proximity
switch 130p can have between a 4 mm to 12 mm range.
[0117] The shaft 108 and hub 109 can be held in a bracket 117 with
an upwardly extending slot 117s with a height "H" that allows the
follower 105 to be positioned at an adjustable height depending on
the size horn in use. The bracket 117 can cooperate with adjuster
bars 127 (FIG. 7B) that secure the follower 105 at a desired
position. The bracket 117 can also include horizontal
(longitudinally extending) channels 117c that allow for
longitudinal positional adjustment.
[0118] The bracket 117 can be held by a main (plate) bracket 112 to
allow the positional adjustment to accommodate different diameter
horns 20. The main bracket 112 can also hold the encoder 145. The
main bracket 112 can cooperate with an encoder clamp plate 145c in
a slot for height adjustment. The main bracket 112 can hold an
encoder mounting bracket 145b in slot 112s to allow for height
adjustment of the encoder 145. As shown, the encoder 145 is a
rotary contact encoder. However, as discussed above, other encoder
or film movement sensor may be used.
[0119] The film follower 105 can have any suitable configuration
but is shown in FIGS. 6, 7A and 7B as having a rounded or arcuate
upper surface 105u that extends laterally across at least a major
portion of the horn diameter thereat. The follower 105 can have a
width (laterally extending) dimension that is between about 0.5-4
inches, for example.
[0120] The casing F can be a multi-layer film comprising at least
two different materials and/or may comprise an aluminum coating
that may be sensitive to sharp bends or folds.
[0121] Referring to FIG. 8, the film drive assembly 45 can
optionally include vacuum drives with belts 45b that contact
opposing sides of the casing on the horn 20 to pull the tubular
casing forward toward the sensor assembly 100 and discharge end of
the horn 20d. The film drive assembly 45 can be configured to
operate with an adjustable drive speed to pull flat stock
casing/film F from a roll of flat stock over the collar 30 and
through the heat-seal assembly 40 to form tubular casing.
[0122] As also shown, two servomotors 200 can be used and may be
synchronized to have the same speed at the same time. However, a
single servomotor 200 can also be used with appropriate gearing and
belts, links or other drive inputs from the motor to the film belts
45b. Further, the servomotors 200 can be configured to extend
upwardly below the vacuum belts 45b as shown. Alternatively, the
servomotor(s) 200 can extend above the belts 45 and even to the
sides of respective belts 45b using appropriate gear boxes to
direct the rotational input to the belts 45b.
[0123] FIG. 9 illustrates the horn 20 with the members 122.sub.1,
122.sub.2 and film drive assembly 45 with servomotors 200 upstream
of the forming collar 30 and an optional pre-heater 50, all held by
a housing 10h so that the discharge end of the horn 20d extends out
of the housing 10h.
[0124] The drive speed can be such that the casing F is advanced
over the forming collar 30 and through the heat-seal heater 40 at a
speed that is typically between about 20-400 ft/min, more typically
between about 20-300 ft/min or between about 20-150 ft/min. In the
upper end of this range, e.g., at about 150 ft/min, the long ends
of the casing are typically under the heat-seal heater 40 for a
short time of between about 0.1 second to about 0.5 seconds. At a
rate of about 150 ft/min, the exposure to the heat-seal heater 40
is about 0.2 seconds.
[0125] In some embodiments, the heat-seal assembly 40 can comprise
a heat-band heater that uses a continuously rotating (endless) heat
seal-band 40b to seal the seam. U.S. Pat. Nos. 5,085,036 and
5,203,760 describe examples of automated, high-speed contact
sealing apparatus forming flat roll stock into tubular film
casings. The contents of these patents are hereby incorporated by
reference as if recited in full herein. However, it is contemplated
that other heat-seal heater configurations or other seal systems
may be used. For example, adhesive seal or tape seal systems can be
used with or without heat-seal assistance. Where used, the
heat-seal heater 40 can comprise rollers or other contact-based
seal mechanisms.
[0126] Referring to FIGS. 10A-10C, the proximity flag member 125
can rotate back and forth in response to movement of the follower
105 up and down. FIG. 10A illustrates the follower 105 in a normal
operative orientation while FIG. 10B illustrates a position of the
flag member 125 over the sensor 130. FIG. 10C illustrates the
follower 105 pushed down with a responsive movement of the flag
member 125 away from the sensor 130, thereby generating a "low
supply" and/or "increase speed" signal. FIGS. 10B and NC show that
the flag member 125 can reciprocate in a longitudinal direction but
other configurations and orientations may be used. Also, in this
embodiment, when the sensor 130 does not detect the flag member
125, the "increase film drive speed" signal is generated. However,
the system 10 can be configured to operate in a reverse
configuration so that when the proximity sensor senses the flag
member 125, the "increase drive speed" signal can be generated.
[0127] In some embodiments, a pulse signal that is externally
applied (when it is the pulse input type) and the rotation detected
by the servomotor encoder, are counted and the difference
(deviation) is outputted to the speed control unit. This counter is
referred to as the deviation counter. During motor rotation, an
accumulated pulse (positioning deviation) is generated in the
deviation counter and is controlled so as to go to zero. The
(position holding by servo control) function for holding the
current position is achieved with a position loop (deviation
counter).
[0128] The forming collar 30 can also be held in a different
orientation from that shown in FIGS. 1, 6, and 9, e.g., rotated to
direct the flat casing long edges together along an outer side or
the bottom with the heat seal heater 40 residing to the side or
under the horn 20, respectively.
[0129] As noted above, the controller 500 can be configured as or
be in communication with a proportional-integral-derivative
controller (PID controller) to have a control loop feedback
mechanism for varying current or power to the servomotor(s) 200 to
maintain a speed and rapidly (instantaneously) increase then
decrease speed.
[0130] The apparatus 10 can form part of a packaging system that
includes a shined voiding/clipping apparatus located downstream of
a respective horn and heat seal assembly 40 to produce an elongated
product. The product can be produced in a linked chain of tubular
or chub product with clips applied at desired intervals. The length
and diameter of each link, chub or discrete product and/or the
overall length of the chain can vary depending on the type of
product being produced. Examples of typical strand or chain lengths
are between about 1-6 feet. See, e.g., U.S. Pat. Nos. 3,543,378,
5,167,567, 5,067,313, and 5,181,302, the contents of which are
hereby incorporated by reference as if recited in full herein.
[0131] The apparatus 10 can be configured to interchangeably
accommodate different size horns 20 and corresponding different
size forming collars 30 that form the suitable size casing. For
example, the diameters of the horns 20 can range between about 1/4
inch to about 8 inches, typically between 3/4 inches to about 5
inches in defined size increments of 1/4 inch, 1/2 inch or 1 inch,
for example. The forming collar 30 will have a width that is larger
than the corresponding horn and typically has about a 3.times.
width as the corresponding diameter of the tubular casing. The
casing contact member(s) 122 can vary in size and/or shape based on
the diameter of the horn 20 and/or target product size.
[0132] The horn 20 can be configured as internal and external
cooperating horns. For example, the internal horn can have a length
that extends through an external heat seal horn 20h (FIG. 9). The
heat seal horn 20h resides at least under the heat seal assembly
40. The horn 20 may be a single horn that can have a different
external shape at the forming collar and/or heat seal assembly 40,
such as a flat surface aligned with the heat seal band to
facilitate heat seal operation.
[0133] Examples of exemplary devices and apparatus used to void,
clip or tension casing material are described in U.S. Pat. Nos.
4,847,953; 4,675,945; 5,074,386; 5,167,567; and 6,401,885, the
contents of which are hereby incorporated by reference as if
recited in full herein. Generally stated, clips can be applied to
the casing material to wrap around and close or seal the product
therein. The seal formed by the clip against the casing may be
sufficiently strong so as to be able to hold a vacuum of about 16
mm Hg for about 24-48 hours. Examples of suitable clips include
metallic generally "U"-shaped clips available from Tipper Tie,
Inc., in Apex, N.C. Other clips, clip materials and clip
configurations may also be used.
[0134] FIG. 11 illustrates a method of steps or actions that can be
used to carry out embodiments of the present invention. Tubular
sealed casing is provided (e.g., film) (block 300). Optionally, the
flat roll stock casing material can be pulled through a forming
collar to form a shaped tubular casing and long edges of the casing
material can be sealed together after the forming collar to provide
the tubular sealed casing (block 302).
[0135] The method can electronically (i) detect when additional
sealed film is needed (block 310) and (ii) direct a servomotor to
increase film-seal speed (block 320).
[0136] The increase can be for a short duration of time under 1
second, typically under 0.2 seconds such as between about 0.1 ms
and about 5 ms, and/or may be to define an adjusted average
"running" or production speed.
[0137] The method can optionally use a sensor or encoder residing
upstream of a casing dancer to control average film speed during
filling (block 303).
[0138] The servomotor can create an instantaneous increase, then
decrease, in casing/film drive speed to temporarily produce
additional heat-seal casing/film to thereby produce sufficient
casing/film for use (block 322).
[0139] The creating step can be carried out without producing
excess tubular casing/film to avoid creating or adding to a buffer
(block 324). Where used, the buffer can be relatively short, e.g.,
between about 1-2 inches that can be created at the beginning or at
different defined times for a single supply of roll stock.
[0140] The method can electronically allow intermittent and
continuous film run modes (block 326).
[0141] The detecting can be carried out using a casing follower
that resides external of and proximate to tubular casing downstream
of the casing/film drive assembly (block 312).
[0142] A signal can be generated to indicate when a short supply
condition exists to cause the electronically directing action
(block 314). The signal can be generated using a proximity switch,
encoder, sensor or other suitable signal generator.
[0143] The casing follower or dancer can be configured to contact
and pivot in response to tautness of casing/film thereat (block
315).
[0144] The casing follower can be in communication with an elongate
arm that moves in response to the pivoting of the follower to
generate a flag signal of "short supply" to cause the servomotor to
increase film/casing drive speed (block 317). The increase may be
for a short time that may be under 1 second, such as, for example,
between about 0.1 ms to about 5 ms, including about 0.2 ms, about
0.3 ms, about 0.4 ms, about 0.5 ms, about 0.6 ms, about 0.7 ms,
about 0.8 ms, about 0.9 ms; about 1 ms, about 1.5 ms, about 2 ms,
about 2.5 ms, about 3 ms, about 3.5 ms, about 4 ms, about 4.5 ms
and about 5 ms.
[0145] At least one clip can be applied to at least one end
portion(s) of a filled length of the sealed casing/film to thereby
seal an end of the filled tubular package (block 328).
[0146] FIG. 12 is a block diagram of exemplary embodiments of data
processing systems 405 in accordance with embodiments of the
present invention. The processor 410 communicates with the memory
414 via an address/data bus 448. The processor 410 can be any
commercially available or custom microprocessor. The memory 414 is
representative of the overall hierarchy of memory devices
containing the software and data used to implement the
functionality of the data processing system 405. The memory 414 can
be non-transitory, and can include, but is not limited to, the
following types of devices: cache, ROM, PROM, EPROM, EEPROM, flash
memory, SRAM, and DRAM.
[0147] As shown in FIG. 12, the memory 414 may include several
categories of software and data used in the data processing system
405: the operating system 452; the application programs 454; the
input/output (I/O) device drivers 458; an Automated Servomotor
Speed Adjustment Module 450 and the data 456.
[0148] The data 456 may include a look-up chart of different casing
run times (i.e., for tubular elastomeric (polymer) casings formed
in situ, as well as the product, filling rates, selectable chain
lengths and link lengths and the like corresponding to particular
or target products for one or more producers.
[0149] As will be appreciated by those of skill in the art, the
operating system 452 may be any operating system suitable for use
with a data processing system, such as OS/2, AIX, DOS, OS/390 or
System390 from International Business Machines Corporation, Armonk,
N.Y., Windows CE, Windows NT, Windows95, Windows98 or Windows2000
from Microsoft Corporation, Redmond, Wash., Unix or Linux or
FreeBSD, Palm OS from Palm, Inc., Mac OS from Apple Computer,
LabView, or proprietary operating systems. The I/O device drivers
458 typically include software routines accessed through the
operating system 452 by the application programs 454 to communicate
with devices such as I/O data port(s), data storage 456 and certain
memory 414 components. The application programs 454 are
illustrative of the programs that implement the various features of
the data processing system 405 and preferably include at least one
application which supports operations according to embodiments of
the present invention. Finally, the data 456 represents the static
and dynamic data used by the application programs 454, the
operating system 452, the I/O device drivers 458, and other
software programs that may reside in the memory 414.
[0150] While the present invention is illustrated, for example,
with reference to the Module 450 being an application program in
FIG. 12, as will be appreciated by those of skill in the art, other
configurations may also be utilized while still benefiting from the
teachings of the present invention. For example, the Module 450 may
also be incorporated into the operating system 452, the I/O device
drivers 458 or other such logical division of the data processing
system 405. Thus, the present invention should not be construed as
limited to the configuration of FIG. 12, which is intended to
encompass any configuration capable of carrying out the operations
described herein.
[0151] The I/O data port can be used to transfer information
between the data processing system 405 or another computer system
or a network (e.g., the Internet) or to other devices controlled or
directed by the processor 410. These components may be conventional
components such as those used in many conventional data processing
systems which may be configured in accordance with the present
invention to operate as described herein.
[0152] For example, the data processing system 405 can be a
computer program product with computer readable program code
configured to provide a plurality of different predetermined
operational modes. In particular embodiments, the computer readable
program code is configured to accept user input to identify the
type of casing material selected for deployment and/or a selection
of the size of the horn or tubular casing. In addition, the
computer readable program code can be configured to inhibit
operation until the door of the machine is closed.
[0153] In addition, the computer readable program code can be
configured to automatically identify when a casing supply is
exhausted. For example, the computer readable program code can be
configured to monitor and/or detect when a limit switch is
triggered responsive to force applied to a lead attached to a
trailing edge portion of the supply of casing material as the
trailing edge portion of the casing material advances.
[0154] While the present invention is illustrated, for example,
with reference to particular divisions of programs, functions and
memories, the present invention should not be construed as limited
to such logical divisions. Thus, the present invention should not
be construed as limited to the configuration of FIG. 12 but is
intended to encompass any configuration capable of carrying out the
operations described herein.
[0155] The operation and sequence of events can be controlled by a
programmable logic controller. The operational mode can be selected
by an operator input using a Human Machine Interface to communicate
with the controller as is well known to those of skill in the
art.
[0156] The flowcharts and block diagrams of certain of the figures
herein illustrate the architecture, functionality, and operation of
possible implementations of selective implementation of single and
dual clip closure means according to the present invention. In this
regard, each block in the flow charts or block diagrams represents
a module, segment, or portion of code, which comprises one or more
executable instructions for implementing the specified logical
function(s). It should also be noted that in some alternative
implementations, the functions noted in the blocks may occur out of
the order noted in the figures. For example, two blocks shown in
succession may in fact be executed substantially concurrently or
the blocks may sometimes be executed in the reverse order,
depending upon the functionality involved.
[0157] The foregoing is illustrative of the present invention and
is not to be construed as limiting thereof. Although a few
exemplary embodiments of this invention have been described, those
skilled in the art will readily appreciate that many modifications
are possible in the exemplary embodiments without materially
departing from the novel teachings and advantages of this
invention. Accordingly, all such modifications are intended to be
included within the scope of this invention as defined in the
claims. In the claims, means-plus-function clauses, where used, are
intended to cover the structures described herein as performing the
recited function and not only structural equivalents but also
equivalent structures. Therefore, it is to be understood that the
foregoing is illustrative of the present invention and is not to be
construed as limited to the specific embodiments disclosed, and
that modifications to the disclosed embodiments, as well as other
embodiments, are intended to be included within the scope of the
appended claims. The invention is defined by the following claims,
with equivalents of the claims to be included therein.
* * * * *