U.S. patent application number 17/110150 was filed with the patent office on 2021-06-10 for pill device apparatus, system and methods for intrusion detection.
The applicant listed for this patent is Dorcia, LLC. Invention is credited to Grant Cook, Thomas Kohlert, Scott Nicholson.
Application Number | 20210169741 17/110150 |
Document ID | / |
Family ID | 1000005420509 |
Filed Date | 2021-06-10 |
United States Patent
Application |
20210169741 |
Kind Code |
A1 |
Cook; Grant ; et
al. |
June 10, 2021 |
PILL DEVICE APPARATUS, SYSTEM AND METHODS FOR INTRUSION
DETECTION
Abstract
The present disclosure is directed to a vent tube apparatus,
system and methods incorporating a ball cage with a modified pill
device design comprising a traceable material such as a Radio
Frequency Identification (RFID) tag for use in conjunction with a
filling machine during container filling operations for a quicker
and more accurate detection of the location of the pill device to
the extent it becomes detached from the ball cage during filling
operations, and to increase the safety of the filling operation and
reduce costs and time when a malfunction occurs.
Inventors: |
Cook; Grant; (Geneva,
IL) ; Kohlert; Thomas; (St. Charles, IL) ;
Nicholson; Scott; (South Elgin, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dorcia, LLC |
Addison |
IL |
US |
|
|
Family ID: |
1000005420509 |
Appl. No.: |
17/110150 |
Filed: |
December 2, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62943025 |
Dec 3, 2019 |
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62955543 |
Dec 31, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61J 7/0436 20150501;
B67C 2003/2657 20130101; A61J 1/03 20130101; A61J 7/0418 20150501;
A61J 7/0076 20130101; B67C 3/2628 20130101 |
International
Class: |
A61J 7/00 20060101
A61J007/00; A61J 1/03 20060101 A61J001/03; B67C 3/26 20060101
B67C003/26; A61J 7/04 20060101 A61J007/04 |
Claims
1. A vent tube and ball cage apparatus for use in filling a
container during a filling process in which the ball cage is
attached to the vent tube, and the vent tube is attached to a
filling machine, comprising: a vent tube body, said vent tube body
being hollow and comprising a vent tube opening, said vent tube
body configured to be attached to a filling machine and configured
to vent a gas from the container during the filling process; a ball
cage, said ball cage comprising an opening, said ball cage attached
to said vent tube body at said vent tube opening; a pill device,
said pill device having an oblong shape and having a bottom portion
that is spherical, said pill device configured to be located inside
said ball cage opening, said pill device further comprising a top
portion, and a cylinder portion, said cylinder portion providing
said oblong shape of said pill device; and an indicator, said
indicator being housed in said pill device, such that if said pill
device is removed from said filling machine, said pill device can
be detected using an indicator detection system.
2. The vent tube and ball cage apparatus in claim 1, wherein said
top portion comprises a beveled edge.
3. The vent tube and ball cage apparatus in claim 1, wherein said
top portion comprises a flat bottom.
4. The vent tube and ball cage apparatus in claim 1, wherein said
top portion comprises a spherical end.
5. The vent tube and ball cage apparatus in claim 1, wherein said
indicator is a Radio Frequency Identification tag.
6. The vent tube and ball cage apparatus in claim 1, wherein said
indicator detection system is a Radio Frequency Identification
reader.
7. The vent tube and ball cage apparatus in claim 1, wherein said
housed in said pill device means enclosed during an injection
molded process.
8. The vent tube and ball cage apparatus in claim 1, wherein said
housed in said pill device means attached during a machining
process.
9. The vent tube and ball cage apparatus in claim 1, wherein said
pill device is prevented from rotating in more than one axis due to
said oblong shape.
10. The vent tube and ball cage apparatus in claim 1, wherein said
indicator is a magnet.
11. A pill device for use with a vent tube and ball cage apparatus
for filling a container in a filling machine in which the vent tube
is configured to vent a gas from the container during a filling
process, comprising: a top portion, a cylinder portion and a bottom
portion, said pill device configured such that said cylinder
portion creates an oblong shape; said pill device configured to be
located in a ball cage opening in said ball cage, such that said
ball cage prevents said pill device from rotating in more than one
axis due to said oblong shape; said bottom portion configured in a
spherical shape; an indicator, said indicator being housed in said
pill device, such that if said pill device is removed from said
ball cage opening, said removal from said ball cage opening can be
detected using an indicator detector.
12. The pill device in claim 11, wherein said top portion comprises
a beveled edge.
13. The pill device in claim 11, wherein said top portion comprises
a flat bottom.
14. The pill device in claim 11, wherein said top portion comprises
a spherical end.
15. The pill device in claim 11, wherein said indicator is a Radio
Frequency Identification tag.
16. The pill device in claim 11, wherein said indicator detector is
a Radio Frequency Identification reader.
17. The pill device in claim 11, wherein said housed in said pill
device housing means enclosed during an injection molded
process.
18. The pill device in claim 11, wherein said housed in said pill
device housing means attached during a machining process.
19. The pill device in claim 11, wherein said indicator is a
magnet.
Description
PRIORITY STATEMENT
[0001] The present application claims the benefit of U.S.
Provisional Patent Application No. 62/943,025, titled Pill Device
Apparatus, System And Methods For Intrusion Detection, filed Dec.
3, 2019, and U.S. Provisional patent Application Ser. No.
62/955,543, titled Pill Device Apparatus, System And Methods For
Intrusion Detection, filed Dec. 31, 2019; all of the foregoing
incorporated by reference herein.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to a novel flat bottom or
oval pill device, ball cage, traceable vent tube, or removable vent
tube tip or cap incorporating one or more detectors or indicators
for use in conjunction with a filling machine during filling
operations to increase the safety of the filling operation and
reduce the associated cost and time when a malfunction occurs.
[0003] The present disclosure relates to food or beverage filling
machines and/or methods utilizing novel flat bottom or oval pill
devices, ball cages, traceable vent tubes, or removable vent tube
tips or caps incorporating a magnet, a Radio Frequency
Identification (RFID) tag, or incorporates other types of tags or
traceable material allowing for a quicker and more accurate
detection of an intrusion and the location of the food or beverage
in which the novel flat bottom and oval pill device, ball cage,
traceable vent tube, or removable vent tube tip or cap, that has
become detached from the filling machine during filling operations,
is located.
[0004] In particular, the present disclosure relates to a
particular design and configuration of a novel flat bottom or oval
pill device, and the related ball cage design and shape that
provides consistent orientation of the pill device and thus a
consistent orientation of the RFID tag, or other detector or
indicator, located in the pill device design. By changing the
current polypropylene ball used in standard operations to the
present novel pill device design and from a spherical to an oval or
oblong shape, with or without a flat bottom, (or other similar
shape), the orientation of the innovative pill device is consistent
such that the magnet or RFID tag located in the pill device design
is always known.
[0005] Once the location of the magnet or RFID tag or other
detector or indicator is consistently known, the antenna or other
indicator reader, detecting the RFID tag or indicator (and thus
detecting the location of the pill device), can accurately and
precisely know if the pill device has successfully entered and left
the canister being filled, or if the pill device has inadvertently
been left behind in a canister or other location.
BACKGROUND OF THE DISCLOSURE
[0006] In the food and beverage industry there is a need for
efficient and reliable manufacturing processes to quickly and
safely manufacture and package the food and beverage product. Most
food and beverage plants across the United States run continuously,
24 hours a day and 7 days a week, to meet the ever-increasing
demands. With these stringent demands on their machines as well as
personnel, most food and beverage plants have implemented some form
of process control or automation. By using programmable logic
controllers (PLCs) and various other logic controlling devices,
elementary applications that used to require manual attention can
now be done with machines.
[0007] In particular, the demand today for beverage containers
filled with product, such as cola and beer, is greater than it has
ever been and continues to grow. These containers can be glass
bottles, aluminum cans or any type of canister that can store, for
example, consumable beverages, automobile product, hair and skin
care product, and any other liquid or semi-liquid product that is
packaged and distributed in such a container. These container
packages can be any size and shape, such as those found in 12-ounce
cola or beer cans and bottles, and the various bottles containing
hair care product. These containers can be made from many different
materials, such as glass, plastic, aluminum, tin among others, and
are enclosed, after being filled with product, using a type of cap
or top attached by screwing onto the container, crimping, pressing
or heat sealing, or in other ways to enclose the product in the
container.
[0008] In order to meet this demand for liquid and semi-liquid
product, high speed, automatic filling machines are incorporated in
the filling process. These automatic machines can load, fill,
enclose, and box up thousands of these containers each minute in a
high-speed operation. These automatic filling machines load the
empty containers onto a conveyor and move the bottles into a
location on the machines where the containers come in contact with
the filling machine and are filled with product. Once filled, the
containers are enclosed or sealed and are quickly moved away from
the filling station, and boxed up or packaged along with other
filled containers to be shipped or distributed to retail centers
and the like.
[0009] In such a high-speed operation, when an accident or mistake
occurs, hundreds or thousands of containers may inadvertently be
filled before the filling machine or process can be halted. In
these situations, the hundreds or thousands of containers filled
after the accident may need to be discarded, wasting time and money
to determine which bottles were filled after the accident.
[0010] The fill process will vary depending on the product being
filled, and various factors, such as the temperature and viscosity
of the product, the beverage gas, the effect of those gases and
related pressure characteristics during the filling process.
Accordingly, the filling process and related conditions can be
optimized and maximized monitoring and controlling these factors.
For purposes of this application and for simplicity, most of the
examples herein will refer to a carbonated beverage filling
process, although the apparatus, system and methods described
herein relate to any similar type of filling process.
[0011] Further, the filling process cannot alter the food or
beverage being filled. Thus, when planning a filling system it is
important to match the appropriate filling steps to the beverage
characteristics and container. The steps of the filling process
include some or all of the following: evacuation of the container,
flushing the container with gas, pressurizing the container with
gas, filling the container with one or multiple speeds, fill level
correction (in certain cases), and settling the product.
[0012] Evacuation is used mostly on rigid containers in which a
vacuum process removes upwards of 90% of the air content in the
container prior to pressurizing with gas. Evacuation becomes more
important when the contents being filled are oxygen sensitive and
the may be repeated at other times throughout the filling process.
Additionally or alternatively, the container may be flushed with
gas. This is done mostly with flexible containers, such as PET
bottles and aluminum cans, which may not be able to withstand a
vacuum. The flushing step takes place at the time that the fill
valve is located at the container and usually uses gas from the
filling ring bowl until both pressures are the same.
[0013] Next, filling takes place when the fill valve opens and the
product flows over, around the vent tube, and into the container.
As the container fills, gas in the containers is displaced by the
product and flows through the vent tube and out of the container
into the filler ring bowl, until the container is full. As an
example, the vent tube may contain an electronic probe to detect
product and stop filling. Accordingly, the vent tube vents the
gases being used while filling the container with fluid. The
process needs to be extremely accurate, and as a result, most vent
tubes are designed at specific lengths to achieve each specific
fill level per filling machine.
[0014] Fill level correction may be incorporated when the cost of
product is high to save product. In the most commonly used fill
level correction step, the container is first overfilled with
product and then the product is extracted using a vacuum through
the vent tube. Finally, by settling, the pressure in the container
is lowered and the beverage is allowed to settle as it is lowered
from the fill valve.
[0015] The vent tubes used in the filling process described above
usually are configured with an elongated, hollow, cylindrical tube
extending the length of the tube, which allows the vent tube to
enter the container opening during the fill process without
touching the container. As described above and in U.S. Pat. No.
3,736,966, which is incorporated by reference herein, the product
can flow over the vent tube into the container. The lower tip of
the vent tube is usually closed and one or more holes are provided
so that any gas or air in the container can be displaced through
the vent tube during the filling process, minimizing or eliminating
the possibility of a container exploding during filling.
[0016] Additionally, vent tubes can be configured for canister
filling by incorporating a ball cage and check ball assembly at the
lower end of the vent tube for preventing gases from leaking during
the filling operation. The ball or sphere is usually made up of a
thermoplastic such as polypropylene, and is captured in the vent
tube ball cage, but is free to move up and down (the z-axis) in the
opening, as understood by one having ordinary skill in the art.
When the ball moves to the top of the ball cage, the ball fits into
the vent tube opening. The circumference of the ball is such that
when it moves to the top of the ball cage, it will block the bottom
of the vent tube opening thereby preventing gases from leaking.
[0017] However, as the captured polypropylene ball moves around in
the vent tube, because the ball is spherical, the ball can rotate
in all directions, in effect rotating inside the vent tube. To the
extent that the polypropylene ball can move on the z-axis, it will
function properly. To the extent that the polypropylene ball
rotates and makes continuous contact with the insides of the vent
tube ball cage, the ball may be deformed or reduced in size over
time, which will lead to the ball falling out of or detaching from
the vent tube ball cage. The ball may thus fall into a canister or
container.
[0018] Traditionally, filling machines for glass containers use a
vent tube made of stainless steel or a stainless food-grade plastic
hybrid. For filling aluminum containers, the vent tube is usually
made from some form of food-grade plastic, such as Delrin.RTM..
Vent tubes can also use a ball and cage system as described in U.S.
Publication No. US20050199314 A1, which is incorporated by
reference herein.
[0019] In certain instances, the high-speed automatic filling
machines allow for removing and replacing the vent tube or a
portion of the vent tube, such as the cap, as described in U.S.
Pat. Nos. 4,049,030 and 5,878,797, which are incorporated by
reference herein. In other situations, a removable vent tube cap or
tip can be attached, either by using threads on the cap, a slot, a
snap-in configuration or some other manner, as understood by one
having ordinary skill in the art.
[0020] Due to the high speeds and constant use of these filling
machines, occasionally a vent tube may detach from the filling
machine and fall into the product container. When either of these
event occur (the ball falling from the vent tube ball cage, or the
vent tube falling from the filling machine), there are minimal
systems in place to halt the filling process, locate the detached
vent tube, or portion thereof (such as a cap) or ball, repair the
filling machine and begin the process again.
[0021] Each minute that the process is halted equates to thousands
of unfilled containers, as filling machines can run at speeds of
1650 cans per minute. Further, the longer the process continues the
more filled containers that will have to be examined to find the
detached vent tube or ball. In many situations, the containers
filled with product that were boxed up or packaged after the vent
tube or ball became detached are merely discarded, increasing the
costs of the accident.
[0022] Similarly, counter pressure fillers or Isobaric Fillers are
devices used to fill bottles or aluminum cans from a pressurized or
non-pressurized bulk storage tank. The goal is to avoid a reduction
in the carbonation of the liquid being filled, as understood by one
having ordinary skill in the art.
[0023] Counter pressure fillers fill containers, canisters or
bottles using a filling tube from the top of the container using a
diffuser to distribute liquid around the walls of the container
while filling. This reduces or avoids foaming of the liquid during
the filling process. The center of the filling tube utilizes a
smaller return tube fitted inside, which allows the carbon dioxide
in the pressurized container to escape to the top of a filling
tank.
[0024] This process provides for more product to fill the container
while the carbon dioxide escapes the container. Although not used
as much, the process can be completed by filling from the bottom
up, but this is more expensive to implement. Fillers have two
inputs--one for the carbon dioxide gas and the other for the actual
liquid. Filler designs also include a vent to allow venting of gas
from the top of the bottle during the filling operation. By
controlling the vent and valves on each input, the pressure and
speed of filling and venting can be controlled.
[0025] In use, a counter pressure filler fills the container by
maintaining constant carbon dioxide gas pressure on the liquid as
understood by one having ordinary skill in the art. The container
is initially pressurized with the carbon dioxide, the fill valve is
opened, and the carbon dioxide is vented to allow the container
bottle to fill from the bottom.
[0026] Some of the current systems used to check for detached
stainless steel vent tubes or the polypropylene ball include the
use of inductive or capacitive sensors, vision systems or other
ultrasonic inline systems. Additionally, systems for determining
when a vent tube or polypropylene ball has become detached and
fallen into a container include the electromagnetic detection
fields or X-ray based technologies. Some of the manufactures of
these technologies include Omron Corporation, Industrial Dynamics
Company, and the Fortress Technology Inc, among others.
[0027] However, most of these inspection systems need to have
direct access to each container after it has been filled with
product, and are used as a way to detect the vent tube or
polypropylene ball by examining each container. This process slows
down the filling line either because each container must be
examined, or takes longer time than necessary to find the container
in which the vent tube or polypropylene ball has fallen if each
container has not been examined.
[0028] Further, some of the systems work better with metal vent
tubes, while other systems work better with plastic vent tubes or
polypropylene balls creating inconsistencies, or the need for
additional equipment when changing to different vent tubes. For
example, when a plastic vent tube or a polypropylene ball falls
into a can made of aluminum at a filling plant, the inductive and
capacitive technologies cannot detect the plastic (foreign) object
through the aluminum can.
[0029] There is currently no apparatus, system or method that
incorporates an indicator or detector, such as an RFID tag or a
magnet, into a novel flat bottom or oval pill device, ball cage,
traceable vent tube, or removable vent tube tip or cap for use
during filling operations, that increases the safety of the filling
operation and reduces the costs and time when a malfunction occurs,
such as when a vent tube or polypropylene ball inadvertently
detaches from the filling machine and falls into the container or
canister.
[0030] There is also no apparatus, system or method relating to
novel flat bottom and oval pill devices, ball cages, traceable vent
tubes, or removable vent tube tips or caps incorporating an RFID
tag or a magnet or another traceable material that allows for a
quicker and more accurate determination of the occurrence and
location of a vent tube or ball that has become detached from a
filling machine during filling operations. The present disclosure
satisfies these needs.
SUMMARY OF THE DISCLOSURE
[0031] In order to solve the above-mentioned shortcomings in
filling operations, the present disclosure utilizes apparatus,
system and/or methods for determining the location of a novel flat
bottom or oval pill device, ball cage, traceable vent tube, or
removable vent tube tip or cap when the filling machine
malfunctions and one of these devices, or a portion thereof,
becomes detached from the filling machine and, in special cases,
falls or intrudes into a container being filled. In particular, the
disclosure utilizes a novel flat bottom or oval pill device, ball
cage, traceable vent tube, or removable vent tube tip or cap
modified in some way with a traceable material, such as an RFID tag
or a magnet, and can incorporate a system and methods for scanning
a filling machine, as well as food or beverage containers, using
sensing technologies, such as RFID technology.
[0032] Additionally, the modified pill device, such as the flat
bottom or oval pill device design, differs from the standard
polypropylene or thermoplastic ball in that the shape of the pill
device is oblong and not spherical. The modified shape allows the
pill device to continue moving in the z-axis inside the ball cage
without tumbling. Thus, the pill device is capable of performing
its intended function of moving up on the z-axis to engage the vent
tube opening to prevent the escaping of gases when needed.
[0033] Although other designs are possible, the modified pill
device design disclosed herein differs from the polypropylene or
thermoplastic ball in that the shape of the pill device is oval or
spherical on the first side and either oval or spherical, or flat
or beveled on the second side, and not spherical on the second
side. As such, the first novel pill device design is oval or
spherical on one side and flat bottom or beveled on the other side,
while the second novel pill device design is oval or spherical on
both sides. Other designs can be incorporated in which the shape
allows the particular device to continue moving in the z-axis
inside a ball cage without tumbling. Thus, the pill device is
capable of performing its intended function of moving up on the
z-axis to engage the vent tube opening to prevent the escaping of
gases when needed.
[0034] The shapes described above also allow for the incorporation
of an RFID tag or another indicator in a location in the novel pill
device such that the RFID tag (or whichever device is used to track
the device), is always in the same relative location in the ball
cage. For example, since the shape of the novel pill device limits
the device rotation inside the ball cage, the RFID tag or other
indicator will always be on a plane perpendicular to the direction
of the vent tube, if that is the desired location. Other
orientations can be used to meet systems requirements. Since the
shape of the novel pill device only allows for rotation or movement
in one axis (besides the z-axis), there will be less contact with
the inside of the ball cage and less damage to the novel pill
device as it is used in the filling operation.
[0035] As such, the present disclosure solves the problems facing
the packaging industry, and in particular, the beverage filling
industry as described above. The present disclosure incorporates a
solution for consistent detection of a novel flat bottom or oval
pill device, ball cage, traceable vent tube, or removable vent tube
tip or cap intrusion into a container, which will exceed the
current standards at specific beverage manufacturing plants.
[0036] At large automated beverage manufacturing plants, aluminum
cans are a commonly used container for product. As described above,
when a plastic vent tube or a propylene ball falls into an aluminum
can as it is being filled, the inductive and capacitive
technologies normally used to detect metal vent tubes or
thermoplastic balls, cannot detect the foreign object through the
aluminum can. As a result, expensive X-ray systems must be used or
the product is considered wasted.
[0037] The present disclosure solves this inherent problem by
incorporating or implementing an RFID tag or a magnet into each
novel flat bottom or oval pill device, ball cage, traceable vent
tube, or removable vent tube tip or cap and associated monitoring
systems. The incorporated RFID tag can be used on metal,
metal-plastic hybrid, ball cage, plastic vent tubes, vent tube caps
and into the novel pill device designs with the same result. By
placing an in-line identification gate or RFID scanner or reader,
or another similar reader, after the filling process occurs, and a
continuous monitoring system on the filling machine any such pill
device, ball cage, traceable vent tube, or removable vent tube tip
or cap can be reliably tracked if it becomes detached from the
filling machine during the filling process.
[0038] By tagging the pill device, ball cage, traceable vent tube,
or removable vent tube tip or cap with an RFID transponder, a
magnet or other tagging technologies, routine consistency checks
will not have to be performed. Further, other materials may now be
considered as containers for the packaging side of the
manufacturing facilities.
[0039] The vent tube and pill device detection systems used in
conjunction with the present disclosure has several components,
such as chips, tags, readers and antennas. By incorporating an RFID
tag, transponder, or other tagging technology into the vent tube or
pill device designs, these devices can be tracked using the same
transponder or tag reading system as described above.
[0040] Since, in the case of an RFID tag, the transponder is
created by attaching a small silicon chip to a small flexible
antenna; the chip can be used to record and store information. To
read the transponder and locate the specific vent tube or pill
device designs, the RFID reader sends out a radio signal to be
absorbed by the antenna and reflected back as a return signal
delivering information from the transponder chip memory.
[0041] In use, the container filling machine operates in its normal
manner with empty containers sent down a conveyor to the filling
section of the system. The vent tube (with or without the pill
device designs) is then lowered (or the empty container is raised)
to come in contact or near contact with the container. The
container is filled with the product as described above, and the
pill device, ball cage, traceable vent tube, or removable vent tube
tip or cap is removed from the filled container. The filled
container is then covered and/or sealed. This filling process fills
thousands of containers each minute.
[0042] In the present disclosure, a traceable vent tube cap can be
attached to an existing vent tube to allow standard vent tubes to
become traceable vent tubes. Alternatively, the modified pill
device design containing a traceable device can be used in a ball
cage instead of a polypropylene ball, to allow standard vent tubes
or ball cages to become traceable vent tubes or ball cages.
[0043] If, during these high-speed operations, a vent tube
malfunctions (i.e., the vent tube, ball cage or pill device
detaches or sheers from the filling machine, and falls into the
container), the RFID transponder incorporated into the vent tube,
vent tube cap, modified pill device (or a combination of the
devices) will likewise fall into the filled container.
[0044] Using the vent tube detection system, the system can have
immediate information that the vent tube has detached from the
filling system and precisely which container the pill device, ball
cage, traceable vent tube, or removable vent tube tip or cap is
located. Depending on the type of system and the indicator being
used, the reader of the vent tube detection system can be anywhere
from 1 foot to 20 to 30 feet from the location of the container or
filling machine. Further, handheld RFID tag or magnetic readers can
be used at the time of the malfunction to assist in finding the
broken pill device, ball cage, traceable vent tube, or removable
vent tube tip or cap.
[0045] The pill device, ball cage, traceable vent tube, or
removable vent tube tip or cap detection system can be set up at
various locations in the filling plant in order to make sure that a
pill device, ball cage, traceable vent tube, or removable vent tube
tip or cap has not become accidentally detached into a filled
container before the container is shipped out of the plant.
[0046] These and other aspects, features, and advantages of the
present disclosure will become more readily apparent from the
attached drawings, the detailed description of the preferred
embodiments, and the recited claims, which follow.
DRAWINGS
[0047] The preferred embodiments of the disclosure will be
described in conjunction with the appended drawings provided to
illustrate and not to the limit the disclosure, where like
designations denote like elements, and in which:
[0048] FIG. 1 illustrates a filling machine in accordance with one
embodiment of the present disclosure;
[0049] FIG. 2 illustrates an inspection system for inspecting empty
and full containers in accordance with the present disclosure;
[0050] FIGS. 3A and 3B illustrate a vent tube incorporating
indicators in accordance with an embodiment of the present
disclosure; and
[0051] FIG. 4 illustrates an exemplary indicator detection system
in accordance with an embodiment of the present disclosure.
[0052] FIG. 5 illustrates an exemplary replaceable and/or traceable
vent tube cap incorporating an indicator in accordance with an
embodiment of the present disclosure.
[0053] FIG. 6 illustrates an exemplary portion of a standard
filling machine indicating a standard vent tube.
[0054] FIG. 7A illustrates an exemplary vent tube ball cage
incorporating a standard ball in accordance with the prior art.
[0055] FIG. 7B illustrates an exemplary vent tube ball cage
incorporating a modified pill device in accordance with an
embodiment of the present disclosure.
[0056] FIGS. 8A and 8B illustrate an exemplary modified pill device
incorporating an oval design in accordance with an embodiment of
the present disclosure.
[0057] FIG. 9 illustrates an exemplary modified pill device
incorporating a flat bottom design in accordance with an embodiment
of the present disclosure.
[0058] FIG. 10 illustrates an exemplary ball cage incorporating a
flat bottom pill device in accordance with an embodiment of the
present disclosure.
DETAILED DESCRIPTION
[0059] As described herein, product, such as cola or beer, is
transferred from the production, brewing or fabrication stage to
the packaging stage to be individually packaged for sale. This
transfer process is known as the fill or filling process and
utilizes automatic high-speed filling equipment to fill and seal
thousands of containers each minute. Often, these automatic filling
machines are of the rotary filler type, which may vary in size from
40, 60, 72, 100, 120 or 180 fill valves and vent tubes per machine,
allowing for the filling of thousands of containers each minute
that the machine is in use.
[0060] FIG. 1 shows a typical rotary bottle or can filler 10, such
as one manufactured by KHS AG, which incorporates vent tubes 12 in
the filling (and venting) process. In general terms and as
described in more detail herein, a vent tube 12 come in contact or
near contact with a container 14 prior to filling the container 14
with the product (not shown). Once a container 14 is in the correct
position, product can be transferred to the container 14 with air
or gas in the container displaced through the vent tube 12. The
container is then sealed or seamed (not shown).
[0061] For glass containers 14, the vent tube 12 is usually made of
stainless steel, but can be made of a food grade plastic, stainless
steel hybrid. For aluminum containers, the vent tube 12 is usually
made of a food grade plastic material. In a vent tube ball cage, a
food grade plastic ball is used to start and stop the flow of
gas.
[0062] Due to the high speeds where thousands and tens of thousands
of containers are filled each minute, and due to the constant use
of these filling machines 10, occasionally a vent tube 12 or other
device used in the filling process, may detach from the filling
machine 10 and fall into the product container 14. If and when this
event occurs, there are a few primitive systems in place to locate
the vent tube 12 and halt the filling process before thousands of
additional containers are filled, making it more difficult to
locate the container 14 with the broken vent tube 12 (or other
device).
[0063] FIG. 2 shows a typical container inspection machine 20, such
as from the manufacturer Industrial Dynamics/filtec, in which each
filled container must pass before each container can be packaged
and distributed. As described herein, these inspection machines 20
utilize various technologies to sense imperfections in the filling
process, including when a foreign material, such as a vent tube,
falls into a container. The technologies include using inductive
and capacitive sensors, vision systems or other ultrasonic inline
systems. However, in most of these systems, each container must be
individually scanned or tested. For example, the vision system
utilizes a light shined through each container (assuming glass or
some other translucent material) and a video/vision camera that
compares the viewed filled container against a table for any
discrepancies. These systems generally slow down the filling
process, are expensive and do not always detect a vent tube 12 that
has inadvertently detached from the filling machine.
[0064] In accordance with the present disclosure, the vent tube (or
other devices as shown in FIGS. 3, 5 and 7-10, and described
herein) used in the fill process is configured to incorporate a
traceable material, such as an RFID tag, a magnet, or in some
cases, both. A scanning system and/or method can then be
incorporated to check for malfunctions in the filling process and
in which container a malfunctioning vent tube has landed. Further,
other types of traceable materials can be used without deviating
from the scope of the disclosure.
[0065] FIGS. 3A and 3B show an exploded view and an assembled view
of a vent tube 16 containing a traceable material, respectively.
The vent tube 16 comprises one or more of an RFID tag 18, a magnet
22, a vent tube head 24, a hollow cylindrical body 26 and
indentations 28 for assisting in connecting to the filling
machine.
[0066] As described herein and in the preferred embodiment, the
vent tube 16 incorporates an RFID tag 18 for detection when the
vent tube detaches from the filling machine 10. The vent tube 16
can be manufactured from material that will be determined by the
standards of the food and beverage industry for each application.
The RFID tag 18 can be attached to, or housed or enclosed in, the
vent tube 16 through a machining or injection molding process as
understood by one having ordinary skill in the art, such that in
the preferred embodiment the RFID tag 18 is attached to, or housed
or enclosed in, the vent tube head 24.
[0067] The vent tube may also incorporate a magnet 22 for
additional detection purposes. In some instances, the vent tube
only uses a magnet 22 and not the RFID tag 18. In accordance with
the present disclosure, an RFID tag or other traceable material 18
can be placed on any type of vent tube used in the filling process,
including vent tube ball cages. Similar to the RFID tag above, the
magnet 22 can be attached to the vent tube 16 in the same manner.
The present disclosure can utilize the RFID tag 18 alone or in
conjunction with the magnet 22.
[0068] RFID systems have several components, such as chips, tags,
readers and antennas, which can be used to determine the location
of an RFID tag (and any item that the tag is attached to) from a
distance away. In its simplest form, a small silicon chip is
attached to a small flexible antenna to create a tag. The chip is
used to record and store information and when a tag is to be read,
the RFID reader or scanner send out a radio signal. The tag absorbs
some of the RF energy from the reader signal and reflects it back
as a return signal delivering information from the tag's
memory.
[0069] The RFID tags 18 do not require a battery, as the power is
supplied by the identification gate as understood by one having
ordinary skill in the art. Any type of RFID tag 18 can be used in
the present disclosure, Ultra-High Frequency (UHF), High Frequency
(HF), and Low Frequency (LF), each providing its own advantages and
disadvantages. The higher the frequency, the longer the range for
detection; while the lower the frequency, the less power that is
needed for the tag to operate. Ranges of 20 to 30 feet are
obtainable for the UHF RFID tags, while the HF and LF RFID tags
operate at approximate distances of 1 meter and 1 foot,
respectively.
[0070] As an example, UHF tags operate within the 800 and 900 MHz
band and provide a response from a range of 20-30 ft. RFID tags
operating in the UHF range can transfer data much faster than RFID
tags operating in the HF and LF bands. However, UHF RFID tags
require more power than those operating at the HF and LF bands, and
are suited more for applications when sensing through low-density
materials.
[0071] RFID tags operating in the HF range primarily operate at
13.56 MHz. These tags require a read distance typically of about 1
meter, and work well when sensing through metal and liquids. RFID
tags operating in the LF band have an operating frequency of 125
kHz and work well sensing through product or materials with a high
concentration of water. These LF tags must be read with equipment
within about a one-foot range. However, these LF RFID tags require
the least amount of power of the three RFID tags described
herein.
[0072] RFID readers or scanners are generally composed of a
computer and a radio. The computer manages communications with the
network or through the Programmable Logic Controller (PLC). The
radio controls communication with the RFID tag, typically using a
language dictated by a published protocol, such as the EPC Class 1
specification.
[0073] When the vent tube 16, or other devices, of the present
disclosure, containing the RFID tag 18, is used in the filling
process, an inspection system, such as an RFID reader, can be
incorporated into the filling line or in numerous other locations
to continuously check for vent tubes 16 that have detached from the
filling machine 10. As soon as a vent tube 16 containing an RFID
tag 18 detaches from the filling machine 10, the RFID reader
determines that the vent tube 16 is no longer in the correct
location and can be used to find the container 14 in which the vent
tube 16 is located. This entire inspection and determination
procedure takes seconds and can be incorporated into the filling
system to immediately shut down the filling process as understood
by one having ordinary skill in the art before many more containers
are filled.
[0074] In an embodiment, the system and methods of the present
disclosure comprise incorporating or housing an RFID tag or
transponder in a stainless steel vent tube, for use in glass bottle
filling for example, and a plastic vent tube, for use in aluminum
can filling for example. The vent tube may also incorporate a
magnet along with the RFID transponder. Using an additional
traceable material, such as a magnet, increases the detection of
the vent tube in certain situations such as when the vent tube
falls into an aluminum can and is sealed attenuating the
signal.
[0075] The embodiment of the system 40 and method is shown in FIG.
4, in which there are three points of detection or identification
of the vent tubes 16 during the filling process. The first point of
detection 42 takes place while the vent tubes 16 are attached to
the filler machine 10. An RFID reader 42 is placed close to the
filler 44 in a section where no containers 14 are present. As the
filler 44 rotates in operation the reader 42 continuously reads the
RFID tags 18 that are imbedded in the vent tubes 16 to ensure one
or more has not become detached during the filling process. This
section 42 of the system 40 will alert the operator if a vent tube
16 becomes detached from the filler 44 and will also provide data
indicating the specific filler vent tube 16 position.
[0076] The second point of detection 46 takes place on the line
after the container 14 has been seamed or sealed. This section 46
of the system 40 utilizes magnetic and inductive sensor
technologies to detect the imbedded magnet 22 in the vent tube 16
(or the stainless steel vent tube). This section 46 of the system
40 provides an output to the operator that can be used in an auto
reject system or at the operator's discretion.
[0077] The third point of detection utilizes a handheld RFID reader
48. After the first 42 or second 46 detection process has
identified a vent tube detachment, the operator can now scan the
specific can or bottle with the handheld scanner 48 in order to
verify the location of the detached vent tube 16.
[0078] The present disclosure does not have to incorporate each of
these detection points, and the system can use one or any
combination of these detection points to detect and locate a
malfunctioning vent tube or a vent tube that has broken off the
filling machine.
[0079] The first point of detection, the RFID reader 42, which
incorporates an antenna, can be integrated (i.e., through an RFID
hardware and/or software integrator) into a local network at the
filling site, or it can be connected through a global
communications network, such as the Internet, to a remote site as
understood by one having ordinary skill in the art. As such, the
information received by the reader 42 at the antenna can be
transmitted to a number of locations for informational purposes
such as record keeping.
[0080] Further, the second 46 and third 48 points can also be
integrated into the system as a whole. Additionally, the system is
not limited to three detection points, as the system is scalable
and additional detection points can be added for other filling
lines and for other scanning purposes, such as to make sure that
none of the filled containers being loaded onto a truck have a
broken vent tube located inside.
[0081] Also, each of the detection points can utilize one or more
of the detection methodologies. So for example, the first point of
detection 42 may only read RFID tags, while the handheld scanner 48
may be configured to scan for both RFID tags and the magnet.
[0082] Other embodiments for determining a malfunction in the
filling process 10, such as a vent tube 16 detaching from a filling
machine 10 and falling into a container 14 include determining the
temperature variant in the bottle as the temperature will change
quickly when a vent tube 16 falls into the container 14 filled with
product. This embodiment employs measuring the temperature variant
in the bottle 14 to detect if a vent tube 16 is present. In a
similar manner, determining the change in bottle 14 capacitance,
whereby the system measures the capacitance and/or change in
capacitance in the bottle 14, can be used to detect an inadvertent
vent tube 16. In this embodiment, a charge is applied to the bottle
14 and the system measures charge or discharge time.
[0083] Another embodiment for detecting a detached vent tube 16
include utilizing an inductive sensor, where a ferrous material 22
is injection molded inside or into the vent tube 16, or a Hall
Effect sensor, where a magnet 22 is injected molded inside or into
a vent tube 16. Additional sensors can be used to detect a modified
vent tube 16 using Ultra Sonic, Infrasonic or Infrared sensors, or
with the use of vision sensors.
[0084] FIG. 5 shows an alternative embodiment in accordance with
the present disclosure. The replaceable and traceable vent tube cap
50 shown from top and side views is also used in the fill process
and is configured to incorporate a housing 52, a traceable material
54, such as an RFID tag, a magnet, or in some cases, both, and a
tapered end 56, for easy insertion into the canister to be filled.
A cavity or evacuation hole 58 there through allows for the
evacuation of air or gas from the canister prior to filling, as
described herein.
[0085] The vent tube cap 50 can be attached to existing vent tubes
in order to retrofit the vent tube to become traceable in
accordance with the monitoring system described herein. The vent
tube cap 50 can be configured with screw threads, a slot or slots,
a snap-in configuration, or some other manner, as understood by one
having ordinary skill in the art, to be attached to the existing
non-traceable vent tube. Other configuration, as described in the
prior art references disclosed above, can be incorporated to allow
the vent tube cap 50 to be attached to the existing vent tube.
[0086] As detailed above, the scanning system 40 and/or method can
then be incorporated to check for malfunctions in the filling
process, and to determine in which container a malfunctioning vent
tube containing a traceable vent tube cap 50 has inadvertently
fallen into the filled bottle, for example. By using the traceable
vent tube cap 50 with an existing non-traceable vent tube, the
retrofit vent tube can now be tracked by the scanning system
40.
[0087] FIG. 6 shows a cutaway portion of a filling machine 10 at
the location in which a container or canister would engage during
the filling process. Each of the quick change valve bells 60 shown
as an example would engage an empty container prior to filling as
described herein. As understood by one having ordinary skill in the
art, each of the bells 60 can be removed (see valve bell 62 for
example) for maintenance or to be replaced with a different device
for filling a different size container. In the center of each valve
bell 60, among other elements, is the vent tube 64. As described
herein, when the container is temporarily connected to the filling
machine, the vent tube 64 evacuates the container while it is being
filled.
[0088] FIG. 7A shows a close up of a standard vent tube 64
comprising a standard ball cage 66 at the lower end 68 of the vent
tube 64 and a ball or sphere 70 captured in the ball cage 66. As
described herein, the ball 70 is usually made up of a thermoplastic
such as polypropylene, and is free to move up and down the z-axis
in the ball cage opening 72, as understood by one having ordinary
skill in the art. When the ball 70 moves to the top of the ball
cage 74, the ball 70, which is configured with a diameter slightly
larger than that of the vent tube opening (not shown), will block
the vent tube opening thereby preventing gases from leaking into
the vent tube 64.
[0089] Because the captured polypropylene ball 70 is spherical, it
can move or rotate around in the vent tube 64. To the extent that
the ball 70 can move on the z-axis, it will function properly. To
the extent that the ball rotates and makes continuous contact with
the insides 76 of the vent tube ball cage 66, the ball 70 may
become deformed or reduced in size over time, which will lead to
the ball falling out of or detach from the vent tube ball cage 66,
creating the problems described herein.
[0090] FIG. 7B likewise shows a close up of a vent tube 64
comprising a ball cage 66 at the lower end 68 of the vent tube 64.
However, the device located inside the ball cage 66 is a modified
pill device that is oblong in shape with oval or spherical ends 78,
different from the ball 70, which is spherical in its entirety. The
pill device is also captured in the ball cage 66, and is usually
made up of a thermoplastic such as polypropylene, although other
materials can be used. The pill device 78 is free to move up and
down along the z-axis, and can rotate in one axis inside the ball
cage opening 72, but cannot rotate in other axes as the spherical
ball 70 can rotate.
[0091] The pill device 78 has a top portion 80 and a bottom portion
82. The top portion 80 is designed with a top end 84 having a
diameter larger than the vent tube opening, such that when the pill
device 78 moves up the z-axis to the top of the ball cage 74, the
pill device 78 will likewise block the vent tube opening thereby
preventing gases from leaking into the vent tube 64.
[0092] FIGS. 8A and 8B show an example of a pill device 78 in
accordance with the present disclosure. The exemplary pill device
comprises two portions, the top portion 80 and the bottom portion
82, along with an RFID tag (or other indicator) 86 that is located
between the top portion 80 and the bottom portion 82. The location
of the RFID tag 86 in between the top portion 80 and the bottom
portion 82, keeps the RFID tag 86 in a consistent and predetermined
plane related to the direction of travel (for example, along the
z-axis) of the pill device 78 inside the ball cage 66 and attached
to the vent tube 64. In doing so, the antenna of the reader 42 will
be able to determine if the pill device 78 is still located in the
vent tube ball cage 66.
[0093] In the example, the top portion 80 comprises the top end 84
and a cylinder portion 88, which lies below the top end 84. It is
the cylinder portion 88, which is configured to keep the pill
device 78 from rotating in an unwanted direction during the filling
process. In the preferred embodiment, the top end 84 has a diameter
of 0.385 inches, and the cylinder portion 88 has a cylinder height
of 0.06 inches, although other sizes and configurations can be
incorporated to keep the RFID tag properly oriented for reading
functionality. The top portion 80 and the cylinder portion 88 can
be two separate pieces or integrated as a single piece. Likewise,
the entire pill device can be molded as a single piece, including
the encapsulation of the RFID tag 86.
[0094] FIG. 9 shows an example of another modified pill device
incorporating a flat bottom and/or a beveled edge 90 in accordance
with the present disclosure. Like the pill device 78, the flat
bottom pill device 90 is oblong in shape, different from the ball
70, which is spherical. The flat bottom pill device 90 can also
captured in a ball cage 66, and is usually made from a
thermoplastic such as polypropylene, although other materials can
be used. The flat bottom pill device 90 is free to move up and down
the ball cage 66 along the z-axis, and can rotate in one axis
inside the ball cage.
[0095] Similar to the pill device 78, the flat bottom pill device
90 has a top portion 92 and a bottom portion 94. The top portion 92
is designed with a top end 96 having a beveled and/or flat portion
98. The bottom portion 94 is oval, curved or spherical with a
radius that is larger than the vent tube opening (not shown), such
that when the flat bottom pill device 90 moves up the z-axis to the
top of the ball cage 74, the bottom portion 94 of the flat bottom
pill device 90 will likewise block the vent tube opening, thereby
preventing gases from leaking into the vent tube 64. In an
exemplary embodiment, the flat bottom pill device 90 has a diameter
of 0.385 inches, with the bottom portion 94 being 0.192 inches high
and having a radius of 0.193. The cylinder portion 88 is 0.134
inches high, and the beveled or flat bottom portion 96 is 0.059
inches high with a beveled edge 98 at 30 degrees, and a bottom edge
diameter of 0.317 inches.
[0096] Similar to the pill device 78, the flat bottom pill device
90 comprises an RFID tag 86 that is located between the top portion
92 and the bottom portion 94. In the exemplary embodiment, the RFID
tag 86 of the flat bottom pill device 90 is 0.060 inches high. The
location of the RFID tag 86 in between the top portion 92 and the
bottom portion 94, and keeps the RFID tag 86 in a consistent and
predetermined plane related to the direction of travel (for
example, along the z-axis) of the flat bottom pill device 90 inside
the ball cage 66 and attached to the vent tube 64. In doing so, the
antenna of the reader 42 will be able to determine if the flat
bottom pill device 90 is still located in the vent tube ball cage
66.
[0097] In the design of the exemplary flat bottom pill device 90,
the top portion 92 comprises the top end 96 and the cylinder
portion 88, which lies at the bottom of the top end 96. It is the
cylinder portion 88 that is configured to keep the flat bottom pill
device 90 from rotating in an unwanted direction inside the ball
cage 66 during the filling process.
[0098] In the exemplary embodiment of the flat bottom pill device
design 90, the top end 96 of the top portion 92 has a diameter of
0.385 inches at its wide end (the same diameter as the flat bottom
pill device design), and 0.317 inches at its narrow end, and a top
end height from top of the top portion to the bottom of the top
portion of 0.059 inches. This configuration creates a 30 degree
beveled edge 98, although other beveled edge configurations will
suffice.
[0099] The top end 96 and the cylinder portion 88 can be two
separate pieces or integrated as a single piece. The bottom portion
94 and the RFID tag 86 can also be two separate pieces or
integrated as a single piece. Likewise, the entire flat bottom pill
device (or any of the individual portions) can be molded as a
single piece, including the encapsulation of the RFID tag 86. Other
sizes and configurations can be incorporated for these designs and
measurements to keep the RFID tag or other indicator properly
oriented for reading functionality during the fill process.
[0100] FIG. 10 shows a vent tube 100 comprising a ball cage 102 at
the lower end 104 of the vent tube 100. However, the device located
inside the ball cage 102 is a modified pill device 90, such as the
flat bottom pill device, that is oblong in shape with an oval or
spherical end 94, and a flat bottom end 96. The flat bottom pill
device 90 is also captured in the ball cage 102, and as described
above, is usually made up of a thermoplastic such as polypropylene,
although other materials can be used. The flat bottom pill device
90 is free to move up and down the ball cage 102 along the z-axis,
and can rotate in one axis inside the ball cage opening 106, but
cannot rotate in other axes as the spherical ball 70 can
rotate.
[0101] The vent tube 100 further comprises a vent tube body 108, a
steam resistant O-ring 110, a hex adaptor 112 and a threaded washer
114. Other parts can be incorporated into the vent tube 100 as
necessary, and the ball cage 102 can be designed longer than a
standard ball cage to provide enough room to allow the flat bottom
pill device 90 (or the other devices described herein) to move
properly in the ball cage 102. Additionally, the lower portion of
the ball cage 102, where the bottom 96 of the flat bottom pill
device 90 rests against it, can be designed or configured to more
closely adapt to the beveled edge 98 of the flat bottom pill device
90. In use, the ball cage is threaded onto the vent tube body 108
after the O-ring 110 has been properly located. The threaded washer
is likewise threaded onto the end opposite the ball cage 102 to the
proper location. Now the vent tube 100 with the flat bottom pill
device 90 can be attached to the filling machine.
[0102] When in use, the spherical end 94 of the flat bottom pill
device 90 is designed with a diameter larger than the vent tube
opening 116, such that when the flat bottom pill device 90 moves up
the z-axis to the top of the ball cage 102, the pill device 90 will
block the vent tube opening thereby preventing gases from leaking
into the vent tube 100.
[0103] It will be understood that the embodiments of the present
disclosure, which have been described, are illustrative of some of
the applications of the principles of the present disclosure.
Although numerous embodiments of this disclosure have been
described above with a certain degree of particularity, those
skilled in the art could alter the disclosed embodiments without
departing from the spirit or scope of this disclosure.
[0104] All directional references (e.g., upper, lower, upward,
downward, left, right, leftward, rightward, top, bottom, above,
below, vertical, horizontal, clockwise, and counterclockwise) are
only used for identification purposes to aid the reader's
understanding of the present disclosure, and do not create
limitations, particularly as to the position, orientation, or use
of the disclosed system and methods.
[0105] Additionally, joinder references (e.g., attached, coupled,
connected, and the like) are to be construed broadly and may
include intermediate members between a connection of elements and
relative movement between elements. As such, joinder references do
not necessarily infer that two elements are directly connected and
in fixed relation to each other. It is intended that all matter
contained in the above description or shown in the accompanying
drawings shall be interpreted as illustrative only and not
limiting. Changes in detail or structure may be made without
departing from the spirit of the disclosed apparatus, system and
methods as disclosed herein.
* * * * *