Abstract:
A system for disconnecting the pump mechanism of the fill system that allows for the removal of the pump mechanism or access to the internal components thereof without removing the supply and dispensing components from the fill system. The disconnect mechanism allows for a valve assembly to be separated from an inlet or outlet to the pump mechanism while the pump mechanism is supported by the mechanism. One disconnect mechanism includes a base, a lifting plate, a cam to move the lifting plate with respect to the base in order to separate the valve assembly from the pump mechanism. Another disconnect mechanism employs a pivot arm having a first end connected to the pump mechanism and a second end in fixed engagement with the valve assembly thereby allowing for the separation of the valve assembly from the pump mechanism.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to an apparatus for filling containers, and more particularly, to a disconnect system for disconnecting the pump mechanism of a fill system used in a packaging machine. The disconnect system facilitates and simplifies the replacement of components of the fill pump mechanism by disconnecting components from the pump mechanism without disconnecting those components from other mating parts of the filling system and without removing them from the packaging machine. 
     Packaging machines are known that integrate the various components necessary to fill and seal a container into a single machine unit. This packaging process, generally stated, includes feeding carton blanks into the machine, sealing the bottom of the cartons, filling the cartons with the desired contents, sealing the tops of the cartons, and then off-loading the filled cartons for shipping. 
     Trends within the field of packaging machines point toward increasingly high capacity machines capable of rapid, continuous filling and sealing of a very large number of identical or similar packaging containers, e.g., containers of the type intended for liquid contents such as milk, juice, and the like. One such machine is disclosed in U.S. Pat. No. 5,488,812, issued Feb. 6, 1996, and entitled &#34;Packaging Machine.&#34; The machine disclosed in that patent includes a plurality of processing stations, each station implementing one or more processes to form, fill, and seal the containers. Each of the processing stations is driven by one or more servomotors that drive the various components of each of the processing stations. 
     Another type of packaging machine is exemplified by the TR/7™ and TR/8™ packaging machines manufactured and available from Tetra Pak, Inc. Such machines are of a more conventional type in which many of the components are driven from a common drive motor through, for example, indexing gears and cam mechanisms. 
     Each of the foregoing systems employ filling systems that utilize fill pump mechanisms. Various systems utilize a diaphragm pump as the pump mechanism. During operation of such a system, a piston is driven so that it alternately compresses and expands a diaphragm that is in fluid communication with the pump head to expel and suction fluid, respectively. Such compression and expansion creates stress on the diaphragm and, as such, the diaphragm must be periodically inspected and/or serviced to ensure proper machine operation. Routine maintenance and repair of the pump mechanisms typically involves a labor and time intensive operation. The numerous interconnected pipes and fittings make easy access to components of the pump mechanism difficult. 
     BRIEF SUMMARY OF THE INVENTION 
     The inventors of the present invention have recognized a need for a disconnect system for disconnecting the pump mechanism of the fill system that allows removal of the pump mechanism or access to the internal components thereof without removing the supply and dispensing components from the fill system. To this end, an apparatus for use in a filling system is set forth. The apparatus comprises a fill pump mechanism having an inlet and an outlet. An inlet pipe is connected to provide a flow of product therethrough. An inlet valve assembly is connected to the inlet pipe to the control flow of the product from the inlet pipe to the inlet of the fill pump mechanism. A fill pipe is connected to provide a flow of product received from the fill pump to, for example, a container disposed on a conveyor beneath the fill pipe. An outlet valve assembly is connected to the fill pipe to control the flow of the product from the outlet of the fill pump mechanism to the fill pipe. A first securement is used for securing the inlet valve assembly to the inlet of the fill pump mechanism during a production cycle of the filling system. The first securement is removable to disconnect the inlet valve assembly from the inlet of the fill pump mechanism during a service cycle of the filling system. A second securement is used for securing the outlet valve assembly to the outlet of the fill pump mechanism during a production cycle of the filling system. The second securement is removable to disconnect the outlet valve assembly from the outlet of the fill pump mechanism during a service cycle of the filling system. A first disconnection mechanism is employed for separating the inlet valve assembly from the inlet of the fill pump mechanism and for supporting the fill pump mechanism and inlet valve assembly in the separated state without removal of components of the fill pump mechanism or inlet valve assembly from the fill system. A second disconnection mechanism is employed for separating the outlet valve assembly from the outlet of the fill pump mechanism and for supporting the fill pump mechanism and outlet valve assembly in the separated state without removal of components of the fill pump mechanism or outlet valve assembly from the fill system. The disconnection mechanisms may both be employed in the fill system or, alternatively, one or the other disconnection mechanism may be employed in a given fill system. 
     In accordance with one embodiment of the first disconnection mechanism, the mechanism comprises a base in fixed alignment with the fill pump mechanism, a lifting plate in fixed alignment with the inlet valve assembly, a cam arranged between the base and the lifting plate, and a mechanism for rotating the cam to move the lifting plate with respect to the base thereby separating the inlet valve assembly from the fill pump mechanism. 
     In accordance with one embodiment of the second disconnection mechanism, the mechanism comprises a pivot arm having a first end connected in fixed alignment with the fill pump mechanism at a pivot joint and a second end in fixed engagement with the outlet valve assembly. 
     The quick disconnect fill system facilitates and simplifies the replacement of components of a fill pump mechanism by allowing the components above and below the pump mechanism to be disconnected from the pump mechanism without disconnecting them from other mating parts and without removing them from the machine. 
     Other advantages of the quick disconnect hinged fill system will become apparent upon reference to the accompanying detailed description when taken in conjunction with the following drawings. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     FIG. 1 is a schematic view of a typical filling machine that may incorporate the presently disclosed quick disconnect system in the fill system. 
     FIG. 2 is a side view of a portion of a filling machine illustrating an embodiment of a quick disconnect system. 
     FIG. 3 is a detail side view in partial cross section of an embodiment of a quick disconnect system, in a connected state, mounted in the fill system. 
     FIG. 4 is a perspective view of an embodiment of a mounting assembly that can be used to support the quick disconnect system of FIG. 3 in the filling machine. 
     FIG. 5 is a side view of an embodiment of the quick disconnect system, in a disconnected state, mounted in the fill system. 
     FIG. 6 is a top view of an embodiment of a motor carriage that can be used to support the quick disconnect system of FIG. 3 in the filling machine. 
     FIG. 7 is a perspective view of an embodiment of a connecting clamp and associated gasket that can be used with the quick disconnect system of FIG. 3 in the filling machine. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 is a partial diagrammatic view of one of the many types of filling machines, shown generally at 10, that may utilize a quick disconnect fill system constructed and operated in the manner described herein. As shown in FIG. 1, a conveyor 15 having a plurality of container support members 20 is driven, for example, by a motor 25, such as a servomotor. The support members 20 each support a single, open topped container 30 that has its bottom sealed. The conveyor 15 is driven by the motor 25 under the control of, for example, a programmable control system 35, or the like, to present the containers 30 successively below a fill pipe 40 of the fill system 10. 
     A storage or balance tank 50 containing a liquid product 55 is connected to provide a flow of the liquid product 55 through a flow control system 60. The flow control system 60, generally stated, comprises an inlet valve assembly 65, an outlet valve assembly 70, a pump mechanism 75, the fill pipe 40, and a nozzle 80. The inlet valve 65 is arranged as part of a product inlet pipe 85. Similarly, the outlet valve 70 is arranged as a part of the fill pipe 40. The inlet valve 65 and outlet valve 70 are operated to control the flow of the liquid product 55 into and from a pump head cavity 90 of a pump head 95 of the pump mechanism 75. The pump mechanism 75 may be any type of pump mechanism, such as one disclosed in U.S. Pat. No. 4,877,160, which patent is incorporated by reference. The pump mechanism 75 may be driven, for example, by a servomotor 100 under the direction of the programmable control system 35. 
     As illustrated, the containers 30 are successively brought below the nozzle 80 for filling with the liquid product 55. To this end, each container 30 is lifted in the direction of arrow 105 so that the nozzle 80 is disposed in the interior of the container 30. This lifting may be done using a lifting mechanism 110 that executes a motion profile under the direction of, for example, the programmable control system 35. The flow control system 60 is then operated to fill the container 30 with liquid product 55 as the container 30 is lowered from the nozzle 80 by the lifting mechanism 110, preferably maintaining the nozzle 80 below the level of the liquid product 55 throughout this downward motion. 
     A fill system having a disconnect system constructed in accordance with one embodiment of the invention is illustrated in FIG. 2 wherein like numerals represent like parts. Generally stated, the disconnect system comprises a fill pump mechanism 115, a product supply system 120, a product dispensing system 125, a first disconnect system 130, and a second disconnect system 135. As will be set forth below in further detail, the first disconnect system 130 allows the product supply system 120 to be disconnected from the input of the fill pump mechanism 115 without requiring the removal of the components of the product supply system 120 from the packaging machine. To this end, the first disconnect system 130 supports both the outlet portion of the product supply system 120 and the fill pump mechanism 115 in the disconnected state. The second disconnect system 135 allows the product dispensing system 125 to be disconnected from the output of the fill pump mechanism 115 without requiring the removal of the components of the product dispensing system 125 from the packaging machine. To this end, the second disconnect system 135 supports both the inlet portion of the product dispensing system 125 and the fill pump mechanism 115 in the disconnected state. 
     In the illustrated embodiment, the fill pump mechanism 115 is comprised of an inlet 140, an outlet 145, a pump head 150 in fluid communication with the inlet 140 and outlet 145, and a pump chamber 155 in fluid communication with the pump head 150. The fill pump mechanism 115 also includes a piston and diaphragm assembly, shown generally at 160, that is driven to expand and reduce the volume of the pump chamber 155 by, for example, a linear drive mechanism, such as a screw-drive that is driven by a servomotor 165. 
     The fill pump mechanism 115 is connected to receive product from the product supply system 120 at the inlet 140. The product supply system of the illustrated embodiment comprises the product supply tank 50, product inlet pipe 85, and inlet valve assembly 65. The fill pump mechanism 115 is also connected to supply product to the product dispensing system 125. In the illustrated embodiment, the product dispensing system comprises the outlet valve assembly 70 and the product outlet pipe or fill tube 40. 
     FIG. 3 is a detail view in partial cross section of the system illustrated in FIG. 2. During a production cycle of machine operation, the liquid product 55 is drawn from the product supply tank 50 into the product inlet pipe 85 and passes through inlet valve assembly 65 into the pump head 150 and pump chamber 155. In this first cycle of operation, the outlet valve 70 is in a closed state. The inlet valve 65 is then closed and the outlet valve 70 is opened while the pump mechanism 115 drives the liquid product out of the pump head 150 and pump chamber 155, through the outlet port 145, outlet valve 70, and the fill tube 40. 
     With reference to both FIG. 3 and FIG. 4, quick release of the fill pump mechanism 115 during a service cycle of the machine is facilitated by the first and second disconnect systems 130, 135. As shown, the inlet 140 of the pump mechanism 115 is connected via a securement, for example, a quick-clamp device 170, to the outlet end of the of inlet pipe 85 of the product supply system 120. The securement 170 is removed to allow the fill pump mechanism 115 to be disconnected from the product supply system 120. In this disconnected state, the first disconnect system 130 supports at least the fill pump mechanism 115 and, preferably, both the fill pump mechanism 115 and the product inlet pipe 85. To this end, a mounting system 175 is provided. The mounting system 175 comprises a mounting bracket 180 that is supported in fixed alignment with the frame of the packaging machine. The mounting bracket 180 supports the fill pump mechanism 115 in the disconnected state. The first disconnect system 130 includes an inlet pipe lifting mechanism shown generally at 190 and is in fixed positional alignment with upper portion of the mounting assembly 180 or pump housing section 315. The lifting mechanism 190 includes a body 195 with a shaft 200. An actuating mechanism 205, for example, a lever is connected perpendicular to the shaft 200 at one end thereof. Near the opposite end of the shaft 200, an eccentric or cam 210 is mounted. In addition, a lifting plate 215 is formed with the inlet valve assembly 65. The eccentric cam 210 is located beneath the lifting plate 215 and is preferably not in contact therewith during normal operation in the connected state shown in FIG. 3. A pivot 220 is arranged on the body 195 of the lifting mechanism 190 and is in contact with the lifting plate 215 so that it forms a fulcrum between the lifting plate 215 and the lifting mechanism 190. 
     Support of the inlet pipe 85 of the product supply system 120 by the first disconnect system 130 is illustrated in FIG. 5. To provide access and clearance for removal of the fill pump mechanism 115, the components above and below the pump head 150 are displaced a sufficient distance to allow the pump head 150 to be removed. In the embodiment shown in FIG. 5, this is done by rotating the lever 205 in a direction indicated by arrow R. This rotation of the lever 205 translates along the shaft 200 into rotation of the eccentric cam 210 into a raised position. In this raised position, the eccentric cam 210 impinges on the underside of the lifting plate 215. The lifting plate 215 is thus lifted up with respect to the pivot 220 in an arc indicated by arrow U in FIG. 5. The components of the product supply system 120 and the components of the fill pump mechanism 115 are thus disconnected and separated from one another without removal of either from the machine. 
     Operation of the second disconnect system 135 is similar to the operation of the first disconnect system 130, except that gravity is used to effect the separation of the outlet 145 of the fill pump mechanism 115 from the product dispensing system 125. To this end, the outlet 145 of the fill pump mechanism 115 is connected via a securement, for example, the quick-clamp device 170, to the inlet of the product dispensing system 125. The securement 170 is removed to allow the fill pump mechanism 115 to be disconnected from the product dispensing system 125. In this disconnected state, the second disconnect system 135 supports both the fill pump mechanism 115 and the product dispensing system 125. In the illustrated embodiment, the mounting bracket 180 maintains its support of the fill pump mechanism 115 while the product dispensing system 125 is supported by a carrying plate 225. The carrying plate 225 comprises an upwardly extending connection port 230 that is secured to the outlet of the outlet valve assembly 70 by a securement 235, such as a quick-clamp device. A retaining pin 240 is arranged in a retaining hole 245 formed in the carrying plate 225. The carrying plate 225 is also pivotably secured with the machine at a pivot connection 250. 
     During a production cycle of the machine, the carrying plate 225 and outlet valve assembly 70 are held by a securement 255, for example, a bolt, so that they are each in fixed alignment with the frame of the machine. To provide for a separation of the fill pump mechanism 115 from the product dispensing system 125 during a service cycle or the like, clamp device 170 is removed. Securement 255 is then loosened. Retaining hole 245 is larger than retaining pin 240 so that gravity causes the components to pivot down about pivot 250 in the direction of arrow D until the edge of retaining hole 245 contacts the retaining pin 240. The product dispensing system 125 thereby separates from the outlet of the fill pump mechanism 115 to facilitate a service operation. 
     FIG. 3 also illustrates one embodiment of a pump mechanism construction that facilitates quick and simplified service and maintenance of the various of mechanism components. Generally stated, the fill pump mechanism 115 is comprised of three seperable components: the pump head 150, a pump chamber cylinder 260, and a motor carriage 265. The cylinder 260 defines the pump chamber 155 which is in fluid communication with the pump head cavity 90. The pump head 150 is in fluid communication with the pump chamber 155 through an aperture. 
     As illustrated in FIG. 3, a flange portion 265 of the pump chamber cylinder 260 abuts a corresponding flange 270 of the pump head 150. The flange portions 265 and 270 are preferably held to one another by a v-band clamp 275. The &#34;v&#34; shape of the v-band clamp 275 advantageously envelops the sides and the top of the two adjacent flanges 265, 270. A similar arrangement at the opposite end of the pump chamber cylinder 260 is provided for the connection between the cylinder 260 and the motor carriage 265. Another v-band clamp 275 wraps around flange portions 265 and 280 of the cylinder 260 and motor carriage 265, respectively. Such an assembly facilitates fast and simple access to the various components of the fill pump mechanism 115, including the diaphragm disposed therein. 
     Referring back to FIG. 4, an embodiment of the mounting assembly 175 for securing and suspending the fill pump mechanism 115 within the filling machine 10 is shown. The mounting bracket 180 includes a support bar 285 extending from a mounting plate 290 to a cantilevered arm 295. In addition, frame members 300 are provided. The mounting plate 290 includes a plurality of mounting posts 305. The mounting posts 305 each preferably include a slot 310. The slot 310 is preferably a machined guide groove. The motor carriage 265 includes a plate portion 315 which is preferably arranged within the slots 310 of the mounting posts 305. This arrangement allows for longitudinal travel of the fill system within the machine 10 to facilitate adjustment of the fill system with respect to, for example, the conveyor 15. Such adjustments are often necessary to compensate for misalignments between the outlet of the fill pipe 40 and the conveyor 15 that occur due to conveyor wear. This manner of adjustment of the fill system with respect to the conveyor 15 has many advantages over prior adjustment methods which only adjusted the position of the fill pipe alone, without a corresponding lateral adjustment of the other components of the fill system. 
     The slots 310 in the four mounting posts 305 also eliminate the need to machine large plate surfaces to obtain a smooth sliding surface. This results in a less costly mounting assembly 175 in terms of machining costs, as well as saving manufacturing time. 
     Referring back to FIG. 3, a piston 320 and a first diaphragm 325 are illustrated which travel within the hollow pump chamber 155 of the cylinder 260 during operation to alternately increase and decrease the volume within the pump head 150. In this arrangement, the piston 320 is reciprocally driven so that it alternately compresses and expands the first diaphragm 325 that is in fluid communication with the pump head 150 to expel and suction the liquid product 55, respectively. 
     FIG. 3 also shows a servo linear actuator system 330 for driving the piston 320 during operation. The linear actuator 330 is connected to the piston 320 via a guide plate 335 and a connection plate 340 held together by a securement 345, for example, a Tri-Clamp™. The connection plate 340 is further secured to the piston 320 by a further securement 350, for example, a bolt. A second diaphragm 355 is arranged between the connection plate 340 and the piston 320. The second diaphragm 355 is also held between the cylinder 260 and the motor carriage 265. An anti-rotation rod 360 and a stationary bushing 365 are also provided. 
     Further, with the pump head 150 removed, the first diaphragm 325 is easily accessible and can be replaced if desired. Also, if further tear down of the quick disconnect fill system is needed, for example, removal of the piston 320 or the second diaphragm 355, the cylinder 260 can be easily disconnected from the motor carriage 265. The v-band clamp 275 connected between the cylinder 260 and the motor carriage 265 can be removed so that the cylinder 260 can be removed as well. 
     Further, as explained above with respect to FIG. 4, the motor carriage 265 is capable of sliding in the slots 310 of the mounting plate 290 of the mounting assembly 175. This capability for movement can be advantageous during the removal and reassembly of the quick disconnect fill system. 
     FIG. 6 illustrates a top view of an embodiment of the motor carriage 265. The motor carriage 265 includes the plate portion 315 which rides within the slots 310. In addition, the motor carriage 265 has a cylindrical body 370 connected to the plate portion 315. The flange portion 280 is formed at an end of the cylindrical body 370 and can be connected via the v-band clamp 275 to the cylinder 260 as shown in FIG. 3. The cylindrical body 370 of the motor carriage 265 also includes a cut-out portion 375 which allows user access to the second diaphragm 355 and piston 320 for repair or replacement. 
     For hygienic operation of the filling system, a shroud or the like may be used to isolate the components disposed above the inlet end of the fill pipe from the containers and associated filling area below the inlet of the fill pipe. To this end, the filling system may include a sterile air flow system such as one disclosed in U.S. Ser. No. , (Attorney Docket No. 11681US01) and U.S. Ser. No. (Attorney Docket No. 11588US01) filed on even date herewith. 
     FIG. 7 illustrates an embodiment of the quick-clamp device, for example, the Tri-Clamp™ 170 suitable for use in the present fill system as shown in FIG. 3. The Tri-Clamp™ 170 is generally round and comprises two semicircular halves 380 and 385. The halves 380 and 385 are joined at a first side by a hinged joint 390 and at a second side by a releasable fastening system 395. The releasable fastening system 395 includes, for example, a screw-type fastener 400 that may be quickly turned by hand, or with the aid of a screwdriver or the like, to secure the ends of the halves 380 and 385 together. The two semicircular halves 380 and 385 also define a channel 405. 
     As illustrated in FIG. 3, the channel 405 of the tri-clamp 170 is arranged and preferably dimensioned to fit over a flange 410 of the inlet valve 65 and a corresponding flange 415 of the pump head 150. A similar arrangement is also provided between the pump head 150 and the outlet valve 70. Such a connection may be provided at further junctions of both the inlet valve 65 and the outlet valve 70 as shown in FIG. 3. 
     In each instance, a gasket 420 engages the channel 405 to ensure a proper seal between the joined flanges. The tri-clamps 170 thus hold the pump head 150 and valves 65, 70 together while also permitting quick disassembly of the pump head and associated components without the use of special tools. 
     While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is therefore contemplated by the appended claims to cover such modifications as incorporate those features which come within the spirit and scope of the invention.