U.S. patent application number 14/695638 was filed with the patent office on 2015-08-27 for high-speed loading / unloading of objects.
This patent application is currently assigned to WILCO AG. The applicant listed for this patent is WILCO AG. Invention is credited to Martin LEHMANN.
Application Number | 20150239674 14/695638 |
Document ID | / |
Family ID | 50545571 |
Filed Date | 2015-08-27 |
United States Patent
Application |
20150239674 |
Kind Code |
A1 |
LEHMANN; Martin |
August 27, 2015 |
HIGH-SPEED LOADING / UNLOADING OF OBJECTS
Abstract
Disclosed are methods and an apparatuses for loading and
unloading objects into/from corresponding cavities in holders at a
high count rate. For loading, a plurality of objects are present on
an object path which mutually converges with a holder path. For
unloading, the object path mutually diverges from the holder path.
Integration of this method and apparatus respectively into a method
of manufacturing unleaky containers and a corresponding apparatus
for leak testing containers is also proposed.
Inventors: |
LEHMANN; Martin; (Wohlen,
CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WILCO AG |
Wohlen |
|
CH |
|
|
Assignee: |
WILCO AG
Wohlen
CH
|
Family ID: |
50545571 |
Appl. No.: |
14/695638 |
Filed: |
April 24, 2015 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
13665042 |
Oct 31, 2012 |
9038257 |
|
|
14695638 |
|
|
|
|
Current U.S.
Class: |
493/37 ;
73/45.1 |
Current CPC
Class: |
G01M 3/00 20130101; Y10T
29/49764 20150115; B65G 17/20 20130101; Y10T 29/49829 20150115;
B65G 17/12 20130101; G01M 3/329 20130101; B65G 17/30 20130101; B65G
37/00 20130101 |
International
Class: |
B65G 37/00 20060101
B65G037/00; B65G 17/12 20060101 B65G017/12; B65G 17/20 20060101
B65G017/20; G01M 3/00 20060101 G01M003/00; B65G 17/30 20060101
B65G017/30 |
Claims
1. Method of manufacturing closed, unleaky containers comprising:
manufacturing closed, untested, containers; loading said containers
into holders; leak-testing said containers in a leak-detection
step; rejecting containers determined as leaking in said
leak-detection step together with their corresponding holder;
unloading unrejected containers from said holders; accepting said
unrejected containers as unleaky containers, wherein said unloading
comprises: conveying holders along a holder path, each holder
comprising at least one cavity, each cavity having an
unloading-direction, and at least some of said cavities comprising
a container loaded in said cavity; picking up said containers
sequentially from the holders in a pickup area; transporting the
collected containers along an object path extending from said
pickup area; configuring said object path and said holder path to
mutually diverge in a direction parallel to said
unloading-direction as distance along said object path from said
pickup area increases; transporting a plurality of containers
simultaneously at different positions along said object path, and
conveying a plurality of holders simultaneously at different
positions along said holder path.
2. Method according to claim 1, wherein the object path is
configured to withdraw from the holder path in a direction parallel
to said unloading-direction as distance along said object path from
said pickup area increases.
3. Method according to claim 1, wherein the holder path is
configured to withdraw from the object path in a direction parallel
to said unloading-direction as distance along said object path from
said pickup area increases.
4. Method according to claim 1, comprising subsequently depositing
said containers in a deposition area downstream of said pickup
area.
5. Method according to claim 1, wherein at least one of said object
path and said holder path is at least one of: linear, curved,
rotary.
6. Method according to claim 1, wherein at least part of said
holders comprise more than one of said cavities, and more than one
of said containers are picked up from said more than one cavities
of said holder.
7. Method according to claim 1, wherein at least one of said
transporting and said conveying is carried out continuously.
8. Method according to claim 7, wherein said transporting and said
conveying are mutually synchronous.
9. Method according to claim 1, wherein respective containers on
the object path travel in said pickup area at a velocity in a plane
perpendicular to the unloading-direction substantially equal to the
velocity in a plane perpendicular to the loading-direction of the
respective holders on the holder path in said pickup area.
10. Method according to claim 1, wherein the object path is
configured to withdraw from the holder path in a direction parallel
to said unloading-direction as distance along said object path from
said pickup area increases and wherein the position of the
containers on the object path in a direction parallel to the
loading-direction is controlled by at least one of: a cam
arrangement, pneumatically, by electric motors, hydraulically.
11. Method according to claim 1, wherein the holder path is
configured to withdraw from the object path in a direction parallel
to said unload-direction as distance along said object path from
said pickup area increases, and wherein the position of the holders
on the holder path in a direction parallel to the loading-direction
is controlled by at least one of: a cam arrangement, pneumatically,
by electric motors, hydraulically.
12. Method of manufacturing closed, unleaky containers comprising:
manufacturing closed, untested, containers; loading said containers
into holders; leak-testing said containers in a leak-detection
step; unloading said containers from said holders; rejecting
containers determined as leaking in said leak-detection step;
accepting unrejected containers as unleaky containers, wherein said
unloading comprises: conveying holders along a holder path, each
holder comprising at least one cavity, each cavity having an
unloading-direction, and at least some of said cavities comprising
a container loaded in said cavity; picking up said containers
sequentially from the holders in a pickup area; transporting the
collected containers along an object path extending from said
pickup area; configuring said object path and said holder path to
mutually diverge in a direction parallel to said
unloading-direction as distance along said object path from said
pickup area increases; transporting a plurality of containers
simultaneously at different positions along said object path, and
conveying a plurality of holders simultaneously at different
positions along said holder path.
13. Apparatus for leak-testing containers comprising: an apparatus
for loading objects into cavities in holders; a leak testing
apparatus situated downstream of the apparatus for loading objects
into cavities in holders; an apparatus for unloading objects from
holders situated downstream of the leak testing apparatus; a
rejection mechanism for rejecting containers determined as leaking
by the leak testing apparatus and operated based on an output
thereof, said rejection mechanism being situated either between the
leak testing apparatus and the apparatus for unloading objects from
holders, or being situated downstream of the apparatus for
unloading objects from holders; a container input for providing
containers as objects to the apparatus for loading objects into
cavities in holders; a container output for receiving containers
from the apparatus for unloading objects from cavities in holders
in turn; a holder conveyor for conveying holders to, through, and
from each of the apparatus for loading objects into cavities in
cavities in holders, the leak detection apparatus, and the
apparatus for unloading objects from holders in turn, wherein said
apparatus for unloading objects from holders comprises: at least
one holder conveyor for conveying holders to, through, and from a
pickup area, each holder having at least one cavity and each cavity
having an unloading-direction; a transport arrangement for
transporting objects from the pickup area, and comprising a
plurality of movable releasable object supports, the positions of
the object supports defining an object path for transporting
objects from the cavities in the holders on the at least one holder
conveyor, said object path and said holder conveyor being
configured to mutually diverge in a direction parallel to said
loading-direction at increasing distance from the pickup area.
14. Apparatus according to claim 13, wherein the holder conveyor is
an endless conveyor.
15. Apparatus according to claim 13, wherein the apparatus for
loading objects and the apparatus for unloading objects both
comprise a rotary holder conveyor and a rotary transport
arrangement.
16. Apparatus according to claim 13, wherein the object supports
are movable at least parallel and perpendicular to the
loading-direction, and wherein the object path is configured to
withdraw from the at least one holder conveyor at increasing
distance from the pickup area.
17. Apparatus according to claim 13, wherein the object supports
are movable at least perpendicular to the loading direction, and
wherein the conveyor is configured to withdraw from the at least
one holder conveyor at increasing distance from the pickup
area.
18. Apparatus according to claim 13, further comprising an object
output defining a deposition area downstream of said pickup
area.
19. Apparatus according to claim 13, wherein at least one of the
holder conveyor and the transport arrangement are at least one of:
linear, curved, rotary.
20. Apparatus according to claim 13, wherein each holder is
provided with more than one of said cavities, and wherein the
transport arrangement is arranged to pick up containers from each
of said plurality of cavities in a respective holder.
21. Apparatus according to claim 13, wherein each holder comprises
a shock-absorbing member of a soft material selected from the group
consisting of nylon, silicone rubber, and natural rubber.
22. Apparatus according to claim 21, wherein the shock-absorbing
member is situated at the open end of the cavity, forming an
extension thereof and being arranged to interact with an abutment
in the form of a flange of a container.
23. Apparatus according to claim 13, wherein the object supports
are movable at least parallel and perpendicular to the
loading-direction, and wherein the object path is configured to
withdraw from the at least one holder conveyor at increasing
distance from the pickup area, and wherein the shape of the object
path is at least partially defined by at least one of a cam
arrangement, hydraulics, pneumatics, and electric motors.
24. Apparatus according to claim 13, wherein the object supports
are movable at least perpendicular to the loading direction, and
wherein the conveyor is configured to withdraw from the at least
one holder conveyor at increasing distance from the pickup area,
and wherein the shape of the holder path is at least partially
defined by at least one of a cam, hydraulics, pneumatics, and
electric motors.
25. Apparatus according to claim 13, wherein the releasable object
supports comprise suction cups or grippers opening parallel or
perpendicular to the insertion direction.
26. Apparatus according to claim 13, wherein the transport
arrangement is arranged to transport respective containers opposite
respective holders and synchronously therewith.
Description
RELATED APPLICATION
[0001] This is a Divisional Application of application Ser. No.
13/665,042 filed Oct. 31, 2012. The disclosure of the prior
application is hereby incorporated by reference herein in its
entirety.
BACKGROUND OF THE INVENTION
[0002] In many production line situations, such as in manufacturing
or testing situations, it is required to load objects such as
containers into cavities in holders therefor, and subsequently to
unload them from the holders. In comparison to merely transferring
such objects from one conveyor to another, this loading in
particular requires relatively precise positioning of the object
such that it is deposited accurately into its cavity in its
respective holder. This is all the more important when the object
is fragile, such as e.g. in the case of glass syringes, since they
must be handled and deposited gently to avoid breakage. Such
holders are used as caddies to transport the objects through at
least part of the manufacturing and/or testing system, and are
commonly known in the field of leak testing as "pucks". It should
be noted that these holders thus do not form part of the consumer
product being manufactured or tested, rather are used to assist in
the holding and transport of the objects through at least part of
the manufacturing or testing system, the objects themselves
constituting at least part of the end product.
[0003] Typically, this is achieved by using a robot to transfer the
objects into the holders by collecting each object from a conveyor
individually and depositing it as gently as required in its
respective holder, before returning to collect another object and
repeat the process. Unloading the objects from the holders is
performed in the reverse sequence. Modern robots are fast enough to
perform these tasks even when the container holders are provided in
a continuously-moving stream. However these processes are still
relatively slow, and depending on the geometry of the loading
arrangement, are limited to loading and unloading about 60 objects
per minute. Furthermore, the movement of the robot is typically
jerky, exhibiting high accelerations, which risks damaging the
objects if they are fragile.
[0004] FIG. 1 illustrates schematically such a prior art
robot-based apparatus for loading objects into holders. Holders 10
provided with cavities 17 are conveyed sequentially in a stream on
a conveyor mechanism 11, which may be of any known type such as
linear, curved, or rotary. Objects 12, which may be of any type or
shape, are conveyed along an object input conveyor 13, from which
they are collected one-by-one by grippers 16 of a robot arm 14 of a
robot 15. These grippers 16 may be of any known type such as
pincers, hooks, one or more suckers, or similar. The robot arm 14
is movable both parallel and perpendicular to the plane of conveyor
mechanism 11, so as to deposit objects 12 into respective cavities
17. After depositing an object 12 in the cavity of a holder 10, the
robot returns to collect another object 12 from the object input
conveyor 13, and the process repeats. If the holders 10 are moving
continuously, the robot arm 14 follows this movement in
synchronicity therewith, and the grippers 16 release the objects 12
either when they have reached their final insertion depth in the
holders 10, or just before such that the object 12 falls a short
distance into its resting place in its respective holder 10.
[0005] Unloading objects 12 from container holders 10 is carried
out by an essentially mirror-image apparatus with the same
components but operated in reverse. In the interests of
conciseness, such a prior art arrangement need not be described
further.
[0006] When utilising such a robot-based system, the only way to
increase the throughput is, besides accelerating operation of the
one robot, to use multiple robots, which is expensive and entails
high maintenance costs and increased risk of parts breakage.
[0007] An object of the invention is thus to overcome the
above-mentioned disadvantages of the prior art and thereby to
provide apparatuses and methods for loading and unloading objects
from cavities in holders at a significantly greater rate than
possible with prior art methods and apparatuses, thereby minimising
acceleration forces exerted upon the objects.
[0008] The invention also concerns the application of these methods
and apparatuses to a method of manufacturing closed, unleaky
containers, and an apparatus for leak testing containers
respectively.
SUMMARY OF THE INVENTION
[0009] An object of the invention is attained by a method of
loading objects into cavities of holders. Holders are conveyed
along a holder path, and each holder comprises at least one cavity
for receiving an object to be loaded into the cavity in a
loading-direction. This loading direction would in practice
normally be perpendicular to the direction of travel of the
holders, however this does not have to be the case.
[0010] In the field of leak testing, these "holders" are commonly
referred to as "pucks".
[0011] Objects are transported along an object path extending to a
loading area. The object path and the holder path are configured to
mutually converge in a direction parallel to the loading-direction
as distance along the object path to the loading area decreases. In
other words the object path and the holder path converge
approaching the loading area. In the loading area, and object is
loaded into a cavity. Importantly, a plurality of objects are
transported simultaneously at different positions along the object
path, and likewise a plurality of holders are conveyed
simultaneously at different positions along the holder path. In
consequence, at any given time a plurality of objects are at
different stages of being transported so as to be loaded into
corresponding cavities in corresponding holders, both along the
loading path and on the loading direction. This thus permits
significantly faster rates of loading than the above-mentioned
prior art robot-based system, in which only a single object is in
the process of being loaded into a cavity at any given time. In
addition, the loading is in consequence smooth and continuous.
[0012] In one embodiment of the above-mentioned methods, the object
path is configured to approach the holder path and in another
embodiment, the holder path is configured to approach the object
path. These two possibilities naturally also include the
possibility of both the holder path approaching the object path
while the object path approaches the holder path.
[0013] In an embodiment of any of the above-mentioned methods, the
method further comprises first collecting objects sequentially from
a collecting area upstream of the loading area, providing a flow of
objects onto the object path.
[0014] In an embodiment of any of the above-mentioned methods,
either the object path, the holder path, or both are linear,
curved, rotary, or any combination thereof. This provides
flexibility in design of the shape of the paths considered in the
loading direction.
[0015] In an embodiment of any of the above-mentioned methods, in
which the object path is at least in the loading area above the
object path, the objects are dropped a non-vanishing specified
distance (measured from their respective cavities and considered
parallel to the loading direction) into their respective cavities.
This prevents object supports from "bottoming out" and risking
pushing the objects too firmly into the cavities, possibly
resulting in damage and/or wear to the mechanism. The objects are
thus released while they are still above their ending position and
fall the last short distance into their respective cavities. In a
further embodiment thereof, the objects are dropped onto a
shock-absorbing member, reducing the risk of damage to the objects
in the case that they are fragile and/or frangible. This
shock-absorbing member can be made of any convenient
shock-absorbing material, such as rubber, nylon, or similar.
[0016] In an embodiment of any of the above-mentioned methods, at
least part of the holders comprise a plurality of cavities, and a
plurality of objects are deposited into this plurality of cavities,
either simultaneously as a batch or sequentially. This enables
increasing the throughput rate of objects even further due to being
able to load more objects into a single holder.
[0017] In an embodiment of any of the above-mentioned methods, the
transporting and/or the conveying is carried out continuously, that
is to say that the objects are loaded in a continuous stream in
quick succession, giving a high throughput rate without a high
acceleration of the objects.
[0018] In an embodiment of any of the above-mentioned methods, the
transporting and conveying are carried out synchronously with each
other. This results in a simple method, since both the transporting
and conveying are fully synchronous with each other, no complicated
arrangements are required to ensure that an object and its
corresponding holder pass through the loading area at exactly the
right velocities, since this is then inherent in the
synchronicity.
[0019] In an embodiment of any of the above-mentioned methods,
respective objects along the object path travel in the loading area
at a velocity in a plane perpendicular to the loading direction
substantially equal to the velocity of the respective holders on
the holder path in the loading area, thus ensuring that the
respective velocities are optimal for easy and safe insertion.
[0020] In an embodiment of any of the above-mentioned methods, the
position of the objects on the object path in a direction parallel
to the loading direction is controlled by at least one of: a cam
arrangement, pneumatically, by electric motors, hydraulically. This
results in simple and reliable control of the position of the
objects.
[0021] In an embodiment of any of the above-mentioned methods, the
position of the holders on the holder path in a direction parallel
to the loading direction is controlled by at least one of: a cam
arrangement, pneumatically, by electric motors, hydraulically. This
results in simple and reliable control of the position of the
holders.
[0022] An object of the invention is likewise attained by a method
of unloading objects from cavities of holders. Holders are conveyed
along a holder path, each holder comprising at least one cavity and
each cavity having an unloading-direction. At least some of the
cavities comprise an object loaded in the cavity. The objects are
picked up sequentially from the holders in a pickup area, and are
transported along an object path extending from the pickup area.
This object path and the holder path are configured to mutually
diverge in a direction parallel to said unloading-direction as
distance along the object path from the pickup area increases, i.e.
the object path and the holder path diverge as they move away from
the pickup area. As above, a plurality of objects are transported
simultaneously at different positions along the object path, and
likewise a plurality of holders are conveyed simultaneously at
different positions along the holder path. In consequence, at any
given time a plurality of objects are at different stages of being
transported so as to be unloaded from corresponding cavities in
corresponding holders. This thus permits significantly faster rates
of unloading than the above-mentioned prior art robot-based system,
in which only a single object is in the process of being unloaded
into a cavity at any given time. In addition, the unloading is in
consequence smooth and continuous.
[0023] In an embodiment of the above-mentioned unloading method,
the object path is configured to withdraw from the holder path in a
direction parallel to the unloading direction as distance along the
object path from the pickup area increases, and in another
embodiment the holder path is configured to withdraw likewise from
the object path. Furthermore, these two embodiments can naturally
be combined so such that both the holder path and the object path
simultaneously withdraw from each other.
[0024] In an embodiment of any of the above-mentioned unloading
methods, the objects are subsequently deposited in a deposition
area downstream of the pickup area, thereby removing the objects
from the object path.
[0025] In an embodiment of any of the above-mentioned unloading
methods, either the object path, the holder path, or both are
linear, curved, rotary, or any combination thereof. This provides
flexibility in design of the shape of the paths considered in the
unloading direction.
[0026] In an embodiment of any of the above-mentioned unloading
methods, at least part of the holders each comprise a plurality of
cavities, and a plurality of objects are picked up from this
plurality of cavities, either simultaneously as a batch or
sequentially. This enables increasing the throughput rate of
objects even further due to being able to hold more objects in a
single holder and unload them therefrom.
[0027] In an embodiment of any of the above-mentioned unloading
methods, the transporting and/or the conveying is carried out
continuously, that is to say that the objects are unloaded in a
continuous stream in quick succession, giving a high throughput
rate.
[0028] In an embodiment of any of the above-mentioned unloading
methods, the transporting and conveying are carried out
synchronously with each other. This results in a simple method,
since both the transporting and conveying are fully synchronous
with each other.
[0029] In an embodiment of any of the above-mentioned unloading
methods, respective objects along the object path travel in the
pickup area at a velocity in a plane perpendicular to the loading
direction substantially equal to the velocity of the respective
holders, holder path in the pickup area, thus ensuring that the
respective velocities are optimal for easy and safe extraction of
the objects from the cavities.
[0030] In an embodiment of any of the above-mentioned unloading
methods, the position of the objects on the object path in a
direction parallel to the unloading direction is controlled by at
least one of: a cam arrangement, pneumatically, by electric motors,
hydraulically. This results in simple and reliable control of the
position of the objects.
[0031] In an embodiment of any of the above-mentioned unloading
methods, the position of the holders on the holder path in a
direction parallel to the unloading direction is controlled by at
least one of: a cam arrangement, pneumatically, by electric motors,
hydraulically. This results in simple and reliable control of the
position of the holders.
[0032] An object of the present invention is likewise attained by
an apparatus for loading objects into cavities in holders. This
apparatus comprises at least one holder conveyor defining a holder
path for conveying holders to, through, and from the loading area.
Each holder has at least one cavity, and each cavity has a loading
direction, in which an object can be loaded. A transport
arrangement is provided for transporting objects into cavities in
the holders on the at least one holder conveyor in the
loading-direction in the loading area. This transport arrangement
comprises a plurality of movable releasable object supports. The
position of the plurality of object supports defines an object
path: when stationary, a curve passing through the plurality of
object supports would define the object path, which likewise
corresponds to the path taken by the object supports when the
apparatus is in operation. This object path and the holder conveyor
are configured to mutually approach in a direction parallel to the
loading-direction as distance to the loading area decreases, i.e.
the object path and the holder conveyor converge in the direction
of the loading area. This enables a plurality of objects to be
transported simultaneously at different positions along the object
path, considered both parallel and perpendicular to the loading
direction, and likewise enables a plurality of holders to be
conveyed simultaneously at different positions along the holder
path. In consequence, at any given time when the apparatus is in
operation, a plurality of objects will be at different stages of
being transported so as to be loaded into corresponding cavities in
corresponding holders. This thus permits significantly faster rates
of loading than the above-mentioned prior art robot-based
apparatus, in which only a single object can be in the process of
being loaded into a cavity at any given time. In addition, the
loading is in consequence smooth and continuous, and the apparatus
is only subjected to minimal accelerations which significantly
increases the maintenance interval of the apparatus.
[0033] In an embodiment of the above-mentioned loading apparatus,
the object supports are movable at least parallel and perpendicular
to the loading-direction, and the object path approaches the at
least one holder conveyor at decreasing distance to the loading
area, and in another embodiment, the object supports are movable at
least perpendicular to the loading direction, and the conveyor is
configured to approach the at least one object path in a direction
parallel to the loading-direction at decreasing distance to the
loading area. These embodiments can naturally be combined such that
both the object path and the holder conveyor mutually converge.
[0034] In an embodiment of any of the above-mentioned loading
apparatuses, the apparatus further comprises at least one object
input for objects which defines a collecting area, this collecting
area being situated upstream of the loading area and from which the
transport arrangement can collect objects.
[0035] In an embodiment of any of the above-mentioned loading
apparatuses, the holder conveyor and/or the transport arrangement
is/are linear, curved, rotary, or any combination thereof. This
provides flexibility in design of the shape of the paths considered
in the loading direction.
[0036] In an embodiment of any of the above-mentioned loading
apparatuses, each holder comprises a shock-absorbing member of a
soft material such as nylon, silicon rubber, or natural rubber.
This shock-absorbing member reduces the risk of damage to the
objects in the case that they are fragile and/or frangible. This
shock-absorbing member can be situated at the open end of the
cavity, forming an extension thereof, and is arranged to interact
with an abutment, such as a flange, of the object. This results in
the flange of the object contacting the shock-absorbing member,
suspending the object from its flange.
[0037] In an embodiment of any of the above-mentioned loading
apparatuses, each holder is provided with a plurality of cavities,
and the transport arrangement is arranged to deposit objects
sequentially or simultaneously as a batch into each of the
plurality of cavities in the respective holder. This enables a
"multiple puck" configuration for improving object throughput
rate.
[0038] In an embodiment of any of the above-mentioned loading
apparatuses not contradicting herewith, the position of the object
supports is controlled at least partially by at least one of: a cam
arrangement, hydraulically, by electric motors, pneumatically. This
enables simple and accurate control of the position of the object
supports.
[0039] In an embodiment of any of the above-mentioned loading
apparatuses not contradicting herewith, the position of the holders
is at least partially defined by at least one of: a cam
arrangement, hydraulically, electric motors, pneumatically. This
enables simple and accurate control of the position of the
holders.
[0040] In an embodiment of any of the above-mentioned loading
apparatuses, the releasable object supports comprise suction cups
or grippers opening parallel or perpendicular to the insertion
direction, enabling reliable gripping of the objects.
[0041] In an embodiment of any of the above-mentioned loading
apparatuses, the transport arrangement is arranged to transport
respective objects opposite their respective holders synchronously
therewith, which provides a simple arrangement for ensuring correct
timing and alignment of the objects and their respective
holders.
[0042] In an embodiment of any of the above-mentioned loading
apparatuses not in contradiction herewith, each holder comprises
more than one cavity, the transport arrangement being arranged to
collect a corresponding quantity of objects from the object input
and then deposit these objects in each of the plurality of cavities
in the respective holder. This permits increased throughput of
objects in the loading apparatus.
[0043] An object of the invention is likewise attained by an
apparatus for unloading objects from cavities in holders. This
apparatus comprises at least for conveying holders to, through, and
from a pickup area, each cavity having an unloading direction. A
transport arrangement is provided for transporting objects from the
pickup area, comprising a plurality of movable releasable object
supports. The positions of these object supports define an object
path for transporting objects from the cavities in the holders on
the holder conveyor, and this transport path and the holder
conveyor are configured to mutually diverge in a direction parallel
to the unloading direction as distance from the pickup area
increases. This enables a plurality of objects to be transported
simultaneously at different positions along the object path, and
likewise a plurality of holders to be conveyed simultaneously at
different positions along the holder path. In consequence, at any
given time when the apparatus is in operation, a plurality of
objects will be at different stages of being transported so as to
be unloaded from the corresponding cavities in corresponding
holders. This thus permits significantly faster rates of unloading
than the above-mentioned prior art robot-based apparatus, in which
only a single object can be in the process of being unloaded from a
cavity at any given time. In addition, the unloading is in
consequence smooth and continuous, avoiding large accelerations,
hence stress on the apparatus is reduced.
[0044] In an embodiment of the above-mentioned unloading apparatus,
the object supports are movable at least parallel and perpendicular
to the unloading-direction, and the object path withdraws from the
at least one holder conveyor at increasing distance from the pickup
area, and in another embodiment, the object supports are movable at
least perpendicular to the unloading direction, and the conveyor is
configured to withdraw from the at least one object path in a
direction parallel to the unloading-direction at increasing
distance from the pickup area.
[0045] These embodiments can naturally be combined such that both
the object path and the holder conveyor mutually diverge.
[0046] In an embodiment of any of the above-mentioned unloading
apparatuses, the apparatus further comprises an object output
defining a deposition area downstream of the pickup area, which
provides a location for the unloaded objects to be output from the
apparatus.
[0047] In an embodiment of any of the above-mentioned unloading
apparatuses, the holder conveyor and/or the transport arrangement
is/are at least one of linear, curved, and rotary. This provides
flexibility in design of the shape of the parts.
[0048] In an embodiment of any of the above-mentioned unloading
apparatuses, each holder is provided with more than one cavity, the
transport arrangement being arranged to pick up objects from each
of the plurality of cavities in a respective holder. This permits
increased throughput of objects.
[0049] In an embodiment of any of the above-mentioned unloading
apparatuses, each holder comprises a shock-absorbing member of a
soft material such as nylon, silicon rubber, or natural rubber.
This shock-absorbing member reduces the risk of damage to the
objects in the case that they are fragile and/or frangible. This
shock-absorbing member can be situated at the open end of the
cavity, forming an extension thereof, and is arranged to interact
with an abutment, such as a flange, of the object. This results in
the flange of the object contacting the shock-absorbing member,
suspending the object from its flange.
[0050] In an embodiment of any of the above-mentioned unloading
apparatuses, the shape of the transport path is at least partially
defined by at least one of: a cam arrangement, hydraulically, by
electric motors, pneumatically. This enables simple and accurate
control of the position of the objects.
[0051] In an embodiment of any of the above-mentioned unloading
apparatuses, the shape of the conveying path is at least partially
defined by at least one of: a cam arrangement, hydraulically, by
electric motors, pneumatically. This likewise enables simple and
accurate control of the position of the holders.
[0052] In an embodiment of any of the above-mentioned unloading
apparatuses, the releasable object supports comprise suction cups
or grippers opening parallel or perpendicular to the insertion
direction, enabling reliable gripping of the objects.
[0053] In an embodiment of any of the above-mentioned unloading
apparatuses, the transport arrangement is arranged to transport
respective objects opposite respective holders synchronously
therewith, which provides a simple arrangement for ensuring correct
timing and alignment of the objects and their respective
holders.
[0054] The invention further relates to a method of manufacturing
closed, unleaky containers comprising first manufacturing closed,
untested, containers. These untested containers are then loaded
into holders by any of the above mentioned methods of loading
objects into cavities in holders, the containers constituting the
objects. Subsequently, these containers are leak tested in a leak
detection step which may be of any known type. Containers
determined as leaking are then rejected together with their
corresponding holder. Non-rejected containers are then unloaded
from their respective holders by any of the above-mentioned methods
of unloading objects from holders, and these non-rejected
containers are then accepted as being unleaky containers.
[0055] An alternate method of manufacturing closed unleaky
containers comprises first manufacturing closed, untested,
containers. These untested containers are then loaded into holders
by any of the above mentioned methods of loading objects into
cavities in holders, the containers constituting the objects.
Subsequently, these containers are leak tested in a leak detection
step which may be of any known type. The containers are then
unloaded from the holders by any of the above-mentioned methods of
unloading objects from holders, after which containers determined
as leaking in the leak detection step are rejected, and containers
not rejected in the previous step are accepted as unleaky
containers.
[0056] The invention further relates to an apparatus for leak
testing containers comprising an apparatus for loading objects into
cavities in holders according to any of the above embodiments
thereof, a leak testing apparatus of any known type downstream of
the loading apparatus, and an apparatus for unloading objects
holders according to any of the above-mentioned embodiments
thereof, situated downstream of the leak testing apparatus. A
rejection mechanism for rejecting containers determined as leaking
by the leak testing apparatus is operated based on an output of the
leak testing apparatus, and is situated either between the leak
testing apparatus and the unloading apparatus, or downstream of the
unloading apparatus. The container input is provided upstream of
the loading apparatus for providing containers as the
aforementioned objects to this loading apparatus, and a container
output for receiving containers from the unloading apparatus is
further provided. Finally, a holder conveyor for conveying the
holders to, through, and from each of the loading apparatus, leak
detection apparatus, and unloading apparatus sequentially is
provided. This apparatus enables high-speed in-line leak testing of
containers which has in practice achieved testing rates of up to
600 containers per minute.
[0057] In an embodiment of the apparatus for leak testing
containers, the holder conveyor is an endless conveyor, i.e. a
conveyor arranged as a circuit, ensuring that the holders loop
around and are automatically recirculated through the
apparatus.
[0058] In an embodiment of the apparatus for leak testing
containers, the apparatus for loading objects and the apparatus for
unloading objects both comprise a rotary holder conveyor and a
rotary transport arrangement. This results in a simple, compact
arrangement.
BRIEF DESCRIPTION OF DRAWINGS
[0059] FIG. 1--schematically, a prior art robot-based apparatus for
loading objects into cavities in holders;
[0060] FIG. 2--schematically, the underlying principle of a first
aspect of the invention for loading objects into cavities in
holders;
[0061] FIG. 3--schematically, the underlying principle of a second
aspect of the invention for loading objects into cavities in
holders;
[0062] FIG. 4--schematically, the underlying principle of a third
aspect of the invention for loading objects into cavities in
holders;
[0063] FIG. 5--schematically, the underlying principle of a fourth
aspect of the invention for unloading objects from cavities in
holders;
[0064] FIG. 6--schematically, the underlying principle of a fifth
aspect of the invention for unloading objects from cavities in
holders;
[0065] FIG. 7--schematically, the underlying principle of a sixth
aspect of the invention for unloading objects from cavities in
holders;
[0066] FIG. 8--schematically, an apparatus for loading objects into
cavities in holders according to the invention;
[0067] FIG. 9--schematically, an apparatus for unloading objects
from cavities in holders according to the invention;
[0068] FIG. 10--schematically, a further apparatus for loading
objects into cavities in holders according to the invention;
[0069] FIG. 11--schematically, a further apparatus for loading
objects into cavities in holders according to the invention;
[0070] FIG. 12--schematically, a further apparatus for loading
objects into cavities in holders according to the invention;
[0071] FIG. 13--schematically, a further apparatus for loading
objects into cavities in holders according to the invention;
[0072] FIG. 14--schematically, a further apparatus for unloading
objects from cavities in holders according to the invention;
[0073] FIG. 15--schematically, a further apparatus for unloading
objects from cavities in holders according to the invention;
[0074] FIG. 16--schematically, a further apparatus for loading
objects into cavities in holders according to the invention;
[0075] FIG. 17--schematically, various forms of holder suitable for
the apparatus of FIG. 16;
[0076] FIG. 18--schematically, a holder suitable for flanged
objects;
[0077] FIG. 19--schematically, a further variation of a holder;
[0078] FIG. 20--schematically, a rotary variant of an apparatus for
loading objects into cavities in holders according to the
invention;
[0079] FIG. 21--schematically, a rotary variant of an apparatus for
unloading objects from cavities in holders according to the
invention;
[0080] FIG. 22--schematically, a leak detection system
incorporating loading and unloading apparatus according to the
invention;
[0081] FIG. 23--schematically, an embodiment of a method of
manufacturing unleaky containers according to the invention;
and
[0082] FIG. 24--schematically, a further embodiment of the method
of manufacturing unleaky containers according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0083] In the figures, like reference signs denote like parts.
[0084] FIG. 2 illustrates schematically and most generically a
first method for loading objects into holders according to the
invention.
[0085] Objects 20, which may have been collected sequentially and
continuously from a collecting area 21, are transported
continuously along an object path 22 extending to loading area 23.
Aside from when collecting the first or depositing the last object
20 in any given batch of operation, a plurality of objects 20 will
be present on object path 22. Meanwhile, holders 10, each having at
least one cavity 17, each cavity being configured to receive an
object 20 and having a loading-direction 24, in which an object 20
is insertable into the cavity 17, are conveyed continuously along
holder path 25 to, through, and from loading area 23.
[0086] Object path 22 approaches the conveyed holders 10, and also
approaches holder path 25, as the holder path 25 and object path 22
approach the loading area 23. In loading area 23 the objects 20 are
loaded into the holders 10 in loading-direction 24. Self-evidently,
objects 20 and holders 10 must pass through loading area 23 at an
appropriate rate, i.e. in the case of one cavity 17 in each holder
10, objects 20 must pass through loading area 23 at the same rate
as holders 10; in the case of two cavities 17 each holder 10,
objects 20 must pass through loading area 23 at double the rate of
the holders 10. In addition, at the point of insertion, the
movement of the objects 20 and the movement of the holders 10 must
be such that insertion of the objects 10 into the cavity 17 can
take place without damaging either the objects 20 or the holders
10. This applies equally to all embodiments.
[0087] FIG. 3 illustrates a variation on the concept of FIG. 2 for
loading objects into containers. In contrast to the embodiment
illustrated in FIG. 2, in FIG. 3 the objects 20 are transported
along the object path substantially on the same level as both the
collection area 21 and the loading area 23, and the holder path 25
approaches the transported objects 20 and the object path 22 as the
holder path 25 and the object path 22 approach the loading area 23,
in which the objects 20 are loaded into the cavity 17 in the
holders 10 in the loading-direction 24. By the term "level", we
understand position parallel to the (un-)loading direction, i.e.
the vertical position as illustrated in the figures.
[0088] FIG. 4 differs from the embodiments of FIGS. 1 and 2 in that
the object path 22 and holder path 25 both mutually converge
towards loading area 23, which is situated at a different level to
both the collecting area 21 and to the holders 10 opposite the
beginning of the object path 22.
[0089] FIG. 5 illustrates schematically the principle of the
invention when applied to a first variation of unloading objects 20
from holders 10. In analogy to FIGS. 2-4, the cavities 17 of the
holders 10 have an unloading-direction 50 in which direction the
objects 20 may be removed from the cavities 17 of the holders 10 in
unloading direction 50. Holders 10, loaded with objects 20, are
conveyed continuously along holder path 25 towards, through, and
from pickup area 51, in which objects 20 are picked up and
extracted from cavities 17 in unloading direction 50. The picked-up
objects are then transported continuously on object path 22, where
they may be deposited at deposition area 52. Downstream of pickup
area 51, the object path 22 recedes from holder path 25, i.e. moves
away from holder path 25 the further it gets from pickup area
51.
[0090] FIG. 6, in analogy to FIG. 3, illustrates a variant method
for extracting objects 20 from holders 10. Holders 10, loaded with
objects 20, are conveyed along holder path 25 to, through, and from
pickup area 51, in which objects 20 are picked up. In contrast to
the embodiment of FIG. 5, holder path 25 recedes from object path
22 as distance from the pickup area 51 increases, thereby
extracting the objects 20 from the holders 10. In this case,
deposition area 52 is on the same level as pickup area 51.
[0091] FIG. 7, in analogy to FIG. 4, illustrates a variant method
for extracting objects 20 from holders 10. In contrast to the
embodiments illustrated in FIGS. 5 and 6, both object path 22 and
conveyance path 25 diverge from their original levels at pickup
area 51, which is at a different level to both deposition area 52
and conveyance path 25 opposite deposition area 52.
[0092] In the above discussion of FIGS. 2-7, it should be noted
that these figures are purely schematic and the particular shapes
of curves, objects, holders, etc. are not be construed as limiting.
Nor is the fact that the methods have been illustrated linearly
limiting: either or both of the holder path and object path may be
curved or rotary, or may even have more complex forms as
required.
[0093] In addition, neither the spacing nor the velocity
perpendicular to the insertion direction of the holders 10 or the
objects 12 need be the same or similar except within the pickup or
deposition area as appropriate.
[0094] FIG. 8 illustrates schematically an embodiment of an
apparatus for loading containers 12 into holders 10 according to
the invention. Conveyor 11 conveys a continuous stream of holders
10 each provided with a cavity 17 in a direction of conveyance 80
underneath transport arrangement 82. Objects 12 are provided at an
object input 81, which may for instance be an object input conveyor
of any known type. Transport arrangement 82 is provided with a
plurality of movable object supports 83 each provided with
releasable grippers 84 which may be of any known type such as
pincers, suction cups, hooks, etc. Containers 12 are collected
sequentially and continuously at object input 81, and are lowered
into cavity 17 in holders 10 continuously. A particularly simple
solution involves conveying containers 10 synchronously with the
movement of movable object supports 83, i.e. respective holders are
conveyed opposite respective object supports at substantially the
same velocity perpendicular to the stems of the object supports 83
and to the insertion direction. However, this does not have to be
the case: so long as the respective velocities of the objects 12
and the holders 10 at the point of loading the objects 12 into the
holders 10 are matched so as to safely load the objects into their
respective cavities 17, the respective velocities of the objects 12
and the holders 10 at other points is irrelevant and can be chosen
at will.
[0095] Once the object 12 has been released by the releasable
grippers 84 into its respective cavity 17, object supports 83 are
withdrawn from the conveyor 11 and are recirculated so as to
collect more objects 12. Upon release, the object 12 may fall a
short distance into the cavity 17, which simplifies adjustment of
the transport arrangement and reduces the risk of damaging or
wearing either the grippers 84 or the containers 12.
[0096] The position of object supports 83, i.e. their extension, is
controlled by any known means, such as one or more cams, a
hydraulic system, electric motors, or a pneumatic system. Such
control systems are well-known to the skilled artisan, and thus
need not be discussed further. The position of the object supports
83 defines the object path as discussed in context of FIGS. 2-7,
and the position of the holders 10 defines the holder path. This
equally applies to all foregoing embodiments.
[0097] FIG. 9 shows an embodiment of an apparatus for unloading
objects 12 from cavities 17 in holders 10 conveyed by conveyor 11.
Transport arrangement 82 is similar to that of FIG. 8, except that
it is arranged to pick up containers 12 from cavities 17 in holders
10 which are conveyed in a direction 90 beneath transport
arrangement 82. In the illustrated embodiment, holders 10 are
provided with an extended opening 91 arranged to support abutments
or flanges 92 on objects 12. For ease of picking up containers 12
from the holders 10, the diameter of the extended openings 91 is
less than that of the flanges or abutments 92, such that grippers
84 can easily hook under flanges or abutments 92 and thereby pick
up containers 12. This, however, is purely illustrative, and any
arrangement is possible, adapted to the exact shape and size and
form of the objects 12 to be picked up. Once picked up, the objects
12 are transferred to object output 93, which may for instance be
an object output conveyor, where they are released by grippers 84.
Object supports are then recirculated and descend towards the
conveyor 11 to pick up more objects 12.
[0098] FIG. 10 illustrates a further embodiment of an apparatus for
loading objects 12 into cavities 17 in holders 10. In contrast to
the embodiment of FIG. 8, the transport arrangement 82 merely
collects objects 12 from object input 81. Holders 10 are conveyed
by a holder conveyor which comprises a plurality of extendable
holder supports 100, which extend to bring the holders 10 up to
meet the objects 12. Objects 12 are released into cavities 17 in
holders 10 by releasing grippers 84 at an appropriate point, from
which the extendable holder supports 100 retract and return the now
loaded holders 10 to their original height. Subsequently, the
extendable holder supports 100 are recirculated to convey further
containers 10. Extendable holder supports 100 are controlled in
their extension by cams, pneumatics, hydraulics, or electric
motors, as is known to the skilled artisan and need not be
discussed further. The position of holder supports 100 defines the
holder path as discussed in context with FIG. 2-7 above.
[0099] FIG. 11 shows a further embodiment of loading objects 12
into holders 10 which differs from that of FIG. 10 in that the
extendable holder supports 100 do not retract with the holders 10
thereupon, rather they deposit loaded holders 10 on a holder output
conveyor 110, and retract and are recirculated thereafter.
[0100] FIG. 12 shows a variant embodiment of loading objects 12
into holders 10, in which both the object holders 83 and the
holders 10 are displaced parallel to insertion direction 24, such
that insertion of the objects takes place at a level different to
both the level of the object input 81 and the starting level of the
holders 10. In this embodiment, once the objects 12 have been
inserted into the holders 10, the holders are released from
extendable holder supports 100 and are deposited on a holder output
conveyor. Subsequently, both object supports and extendable holder
supports 100 retract and are recirculated.
[0101] FIG. 13 illustrates a further embodiment for loading objects
12 into holders 10 which differs from that of FIG. 12 in that,
after depositing the objects 12 into the holders 10, both the
object supports 83 and the extendable holder supports 100 retract,
returning the loaded holders 10 to their original level.
[0102] FIG. 14 illustrates a further embodiment for unloading
objects 12 from holders 10, in which object supports 83 are not
extendable, and remain at the same level. Extendable holder
supports 100 extend towards object supports 83 such that grippers
84 can pick up the objects 12. Subsequently, extendable holder
supports 100 and corresponding holders 10 withdraw from object
supports 83 and return to their original level. Picked-up objects
12 are deposited at object output 93.
[0103] FIG. 15 illustrates a variant embodiment of FIG. 14 in which
object supports 83 are additionally extendable, and extend towards
holders 10. After picking up objects 12, both object supports 83
and extendable holder supports 100 and respective holders 10
withdraw to their original levels, and objects 12 are then
deposited on object output 93. Other variants are naturally also
possible, such as situating the object output 93 at a level
different to that of both the starting position of object supports
83 and the starting position of holders 10.
[0104] FIG. 16 illustrates schematically an embodiment permitting
to further increase throughput of objects 12, illustrated here in
analogy to the embodiment of FIG. 8, however the illustrated
principle is equally applicable to all loading and unloading
apparatuses described in the specification. The apparatus of FIG.
16 differs from the foregoing embodiments in that each holder 10
comprises a plurality of cavities, illustrated in FIG. 16 as to
cavities, arranged in the direction of conveyance 80 of the holders
10. Object supports 83 comprises a pair of grippers 84 which
simultaneously collect to objects 12 from object input 81 and
deposit them simultaneously in their respective holder 10.
[0105] FIG. 17 illustrates schematically three variations of
holders for use in the embodiment of FIG. 16. Holder 171 comprises
two cavities 172 arranged parallel to direction of conveyance 80.
Holder 173 comprises two cavities 172 arranged perpendicular to
direction of conveyance 80. Holder 174 comprises four cavities
arranged in a square. Both holders 173 and 174 will require object
input 81 to present objects 12 in two parallel lines such that they
can be collected by object supports 83. The exact shape and form of
cavities 172 can be arranged as required by the skilled Artisan for
the objects in question, and the number and arrangement of cavities
can likewise be arranged as required.
[0106] FIG. 18 illustrates a specific example of a holder 10 and an
object 12. In this figure, object 12 is a container with a flange
12a, such as a filled or unfilled glass syringe. Holder 10 has a
body 160 with a cavity 161 formed therein. Cavity 161 is conformed
so as to be a loose sliding fit for container 12, and is
illustrated in FIG. 18 as being a blind hole, however it could
equally be a through hole. The mouth of the cavity is provided with
an extension 162, illustrated here as a separate piece made of a
soft material such as nylon, silicon rubber, natural rubber, or
other sufficiently soft material, against which the flange 12a of
container 12 can abut. Thereby, extension 162 acts as a buffer
during loading of container 12 into holder 10, reducing the risk of
breaking container 12 during insertion. For less fragile objects
than glass syringes, extension 162 may be constructed of harder
material, or formed integrally with the body 160. To permit a
gripper to be able to easily grab container 12, the outer diameter
of the extension 162 is less than the diameter of the flange 12a,
permitting easy extraction of the container from the holder 10. To
permit use of the holder with pressure-based leak-testing systems
such as those commercialised by the Applicant, at least one lateral
through hole 163 is provided in extension 162 to permit
equalisation of the pressure between the cavity 161 and the
pressure in a test chamber (not illustrated). Thereby, holder 10
can be used as a so-called "puck" (i.e. a container holder) in such
a pressure-based leak detection system as mentioned above, in which
the holder 10 may be introduced into a test chamber, or may itself
form part of a test chamber.
[0107] Naturally, the skilled artisan knows how to configure a
holder 10 for a given object 12, and a further example is given in
FIG. 19, which shows a holder 10 configured for a fragile
cylindrical object 12. Holder 10 has a body 160 provided with a
closed-ended cylindrical cavity 161, with buffer 164 of soft
material such as nylon, silicon rubber, or natural rubber situated
at the closed end of the cavity 161. For less fragile objects,
buffer 164 may be eliminated.
[0108] FIG. 20 shows schematically a practical example for loading
flanged objects 12 such as glass syringes into holders 10 of the
type illustrated in FIG. 18, utilising the loading scheme of FIGS.
2 and 8 and implemented with a rotary conveyor 11. Object input 81,
such as a conveyor, presents objects 12 to the grippers 84 of
object supports 83 provided on an object support rotor 180. Coaxial
with the object support rotor 180 is rotary conveyor 11, and both
object support rotor 180 and rotary conveyor 11 rotate
synchronously with each other at the same angular velocity, either
driven by a common drive or by two separate drives (not
illustrated). Rotary conveyor 11 may be, as is common, a star gear
or any other convenient known arrangement. Holders 10 are
introduced onto rotary conveyor 11 at 181, e.g. by a conveyor, and
leave rotary conveyor 11 at 182, again e.g. by a conveyor. As the
rotary conveyor 11 and the object support rotor 180 rotate, objects
12 are collected at 183 and are gently lowered into the cavities 17
of the holders 10. At around position 184, at least the tip of the
object 12 has already entered the cavity 17 in the corresponding
object holder 10, and is released by the gripper 84 of the
corresponding object support 83. If the object 12 has not been
fully lowered into its cavity 17, it is allowed to fall a short
distance, and to seat under the force of gravity. Subsequently,
object holders 83 retract and travel further around the rotor to
pick up another object 12. The loaded holders 10 then leave the
rotary conveyor 11 at 182.
[0109] As previously discussed, the extension and retraction of the
object supports 83 may be controlled by one or more cams,
pneumatically, by electric motors, or hydraulically, according to
the desires of the process operator. These control systems are
well-known to the skilled Artisan and need not be discussed
further. Furthermore, the form of the grippers and the shape of the
holders 10 may be adjusted as required for any given form of object
12: for instance, grippers 84 may be one or more suction cups,
hooks, etc.
[0110] FIG. 21 illustrates schematically a rotary object unloading
system analogous to the loading system of FIG. 20. Rotary conveyor
11 and object support rotor 180 are essentially the same as those
in FIG. 20.
[0111] Loaded holders 10 enter the rotary conveyor 11 at 191 and
are conveyed therearound. Object supports 83 extend and pick up
objects 12 at point 193, and then subsequently retract with the
object 12, which are deposited on object output 93, which is for
instance a conveyor. Meanwhile, unloaded holders 10 exit the rotary
conveyor at 192.
[0112] As previously discussed, the extension and retraction of the
object supports 83 may be controlled by one or more cams,
pneumatically, by electric motors, or hydraulically, according to
the desires of the process operator. These control systems are
well-known to the skilled Artisan and need not be discussed
further. Furthermore, the form of the grippers and the shape of the
holders 10 may be adjusted as required for any given form of object
12: for instance, grippers 84 may be one or more suction cups.
[0113] FIG. 22 illustrates schematically a container leak detection
system incorporating an apparatus for loading objects into
containers according to the invention, and an apparatus for
unloading objects from containers according to the invention. The
dashed line 200 illustrates the passage of holders through the
system, and the objects are closed containers.
[0114] An apparatus for loading objects into cavities in holders
(loading apparatus 201), which may be that as illustrated in FIG.
20, loads containers presented by an object input conveyor 81 into
holders. The thus loaded holders exit loading apparatus 201 at
loading apparatus output 202 and enter test cavities of the rotor
204 of a leak detection apparatus at test rotor input 203. As they
travel around rotor 204, they are leak tested according to any
known method, for instance (but not limited to) one or more of the
methods disclosed in one or more of U.S. Pat. No. 5,907,093, U.S.
Pat. No. 6,082,184, U.S. Pat. No. 6,202,477, U.S. Pat. No.
6,305,215, U.S. Pat. No. 6,439,033, U.S. Pat. No. 6,575,016, U.S.
Pat. No. 6,829,936, WO 2011/012730, U.S. Pat. Nos. 7,000,456,
6,446,493 or U.S. Pat. No. 6,185,987, which are herein incorporated
by reference insofar as they relate to leak testing, and after
testing, the holders leave rotor 204 at test rotor output 205.
Based on the result of leak testing, containers deemed to be
leaking are rejected in their holders by rejection mechanism 206,
and are transported to rejection output 207. Containers not deemed
to be leaking then enter in their holders at unloading apparatus
input 208 an apparatus for unloading objects from cavities in
containers (unloading apparatus 209), which may be that illustrated
in FIG. 21, where they are unloaded from the corresponding holders
and/or output at object output 93. The thus unloaded holders then
leave the unloading apparatus 209 at unloading apparatus output
210, and then travel around to re-enter loading apparatus 201 at
loading apparatus input 211, to repeat the process.
[0115] Variations on the system illustrated in FIG. 22 are as
follows: rejection mechanism 206 may be integrated into object
output 93 so as to reject individual containers after unloading;
the shape of the path 200 of the containers can be arranged at
will; object loading apparatus 201 may be linear rather than
rotary, as may object unloading apparatus 209 and leak detection
apparatus.
[0116] FIG. 23 illustrates schematically a method of manufacturing
unleaky containers according to the invention.
[0117] Untested containers 12u are manufactured at 230 and are
loaded into corresponding holders 10 according to one of the
above-mentioned methods by one of the above-mentioned apparatuses
in 231. In 232, the untested containers 12u are leak tested as
discussed above, and rejection mechanism R rejects containers
detected as leaking based on an output 232.sub.o of the leak test.
Subsequently, unleaky containers 12g are unloaded from their
corresponding holders 10 at 233, and are output for further
manufacturing, labelling, boxing, shipping, etc. Empty holders are
returned to the loading block 231 such that they re-cycle through
the system.
[0118] FIG. 24 illustrates schematically a further method of
manufacturing unleaky containers according to the invention, which
differs from that of FIG. 23 in that the rejection mechanism R is
situated after the unloading step 233. Thus all containers 12 are
unloaded from the corresponding holders 10, after which rejection
based on the output 232.sub.o of the leak detection in 232 takes
place. As above, empty holders are returned to the loading block
231 such that they cycle through the system.
[0119] While a full attempt has been made to describe the invention
by means of various specific embodiments, these are not to be
construed as limiting the scope of the invention, which is defined
solely by the scope of the appended claims. In particular, it is
noted that all embodiments may be combined as long as the result is
not contradictory.
* * * * *