Container filling machine

A vibration tray assembly for use in a container filling machine, the vibration tray assembly comprising a tray for transporting discrete articles from a receiving end of the tray towards a drop-off end of the tray, the tray providing a slope along which the discrete articles travel from the receiving end of the tray to the drop-off end of the tray, wherein the tray is adjustable for changing the slope along which the discrete articles travel. The vibration tray assembly further comprises a vibration imparting device for imparting vibrational motion to the tray.

FIELD OF THE INVENTION

The present invention relates generally to the field of container filling machines for filling containers with discrete articles, and specifically to container filling machines that comprise discrete article dispensing devices for supporting the weight of a load of discrete articles, and adjustable vibration trays for providing different slopes along which discrete articles can travel towards the containers being filled.

BACKGROUND OF THE INVENTION

Container filling machines for filling containers with discrete articles (such as pharmaceutical pills, cosmetic items, hardware components, candies, nuts, etc. . . . ) are known in the art. Such container filling machines are able to take a large supply of discrete articles and transport them towards a container. However, existing container filling machines are plagued with numerous deficiencies that often render them ineffective and inefficient. This is detrimental in a field where the speed

Existing container filling machines use large hoppers in order to hold a load of discrete articles that are to fill one or more containers. The hoppers dispense the discrete articles onto a transporting surface of the container filling machine, such that the transporting surface is able to move the discrete articles towards the one or more containers and create space between each discrete article. However, a deficiency with existing hoppers is that they dispense the discrete articles onto the transporting surface in such a way that the weight of the load of discrete articles contained within the hopper is transferred directly to the transporting surface. This may cause undue wear on the container filling machine, and may also hinder the exit of the discrete articles from the hopper onto the transporting surface.

Furthermore, existing container filling machines typically use vibration trays in order to create space between the discrete articles and move the discrete articles forward towards the containers to be filled. However, the speed at which such vibration trays are able to move the discrete articles forward is generally quite limited. In addition, the speed at which the vibration trays are able to move different types of discrete articles varies depending on the discrete article being handled. For example, while the vibration trays may be able to move small circular discrete articles forward fairly quickly, the same vibration tray may not be able to move a different type of discrete article, such as a larger oval-shaped discrete article, as quickly. As such, traditional vibration trays are not particularly versatile when it comes to handling multiple different types of discrete articles.

In light of the above, it is clear that there is a need in the industry for an improved container filling machine that alleviates, at least in part, the deficiencies of existing container filling machines, and provides more versatility in being able to process discrete articles of different shapes and sizes.

SUMMARY OF THE INVENTION

In accordance with a first broad aspect, the present invention comprises a vibration tray assembly for use in a container filling machine, the vibration tray assembly comprising a tray for transporting discrete articles from a receiving end of the tray towards a drop-off end of the tray, the tray providing a slope along which the discrete articles travel from the receiving end of the tray to the drop-off end of the tray, wherein the tray is adjustable for changing the slope along which the discrete articles travel. The vibration tray assembly further comprises a vibration imparting device for imparting vibrational motion to the tray.

In accordance with a second broad aspect, the present invention comprises a container filling machine for filling a plurality of containers with discrete articles. The container filling machine comprises a vibration tray assembly, a discrete article dispensing device for providing discrete articles to the receiving end of the tray and a plurality of pathways for receiving the discrete articles from the drop-off end of the tray, the plurality of pathways leading to at least one container to be filled with the discrete articles. The vibration tray assembly comprises a tray for transporting discrete articles from a receiving end of the tray towards a drop-off end of the tray, the tray providing a slope along which the discrete articles travel from the receiving end of the tray to the drop-off end of the tray, wherein the tray is adjustable for changing the slope along which the discrete articles travel. The vibration tray assembly further comprises a vibration imparting device for imparting vibrational motion to the tray.

In accordance with a third broad aspect, the present invention comprises a method for filling at least one container with discrete articles, wherein the discrete articles are transported towards the at least one container via a vibration tray. The method comprising determining a characteristic associated with at least one discrete article from a load of discrete articles intended to fill the at least one container, determining, at least in part on a basis of the characteristic, a position for the vibration tray, such that the vibration tray acquires a given slope along which the discrete articles travel from a receiving end of the vibration tray to a drop-off end of the vibration tray, the given slope being one of at least two possible slopes and causing the vibration tray to acquire the given slope.

In accordance with a fourth broad aspect, the present invention comprises a discrete article dispensing device comprising a receptacle for holding a load of discrete articles and a dispensing outlet through which discrete articles from the load of discrete articles exit the receptacle onto a discrete article transporting surface, the dispensing outlet defining a slot between a first wall portion of the discrete article dispensing device and a second wall portion of the discrete article dispensing device and a ramp portion that extends past the slot for depositing discrete articles from the load of discrete articles onto a discrete article transporting surface.

In accordance with a fifth broad aspect, the present invention comprises a container filling machine for filling a plurality of containers with discrete articles. The container filling machine comprises a discrete article dispensing device comprising a receptacle for holding a load of discrete articles for filling the plurality of containers and a dispensing outlet through which discrete articles from the load of discrete articles exit the receptacle, the dispensing outlet defining a slot between a first wall portion of the discrete article dispensing device and a second wall portion of the discrete article dispensing device, and a ramp portion that extends past the slot for guiding the discrete articles out of the discrete article dispensing device. The container filling machine further comprising a discrete article transporting surface for receiving the discrete articles from the discrete article dispensing device and for guiding the discrete articles towards the plurality of containers.

In accordance with a sixth broad aspect, the present invention comprises a method comprising receiving, at a processing entity, a characteristic associated with at least one discrete article from a load of discrete articles, the load of discrete articles being held in a discrete article dispensing device. The discrete article dispensing device comprising a receptacle for holding the load of discrete articles, a dispensing outlet through which the discrete articles from the load of discrete articles exit the receptacle onto a discrete article transporting surface, the dispensing outlet defining a slot between a first wall portion of the discrete article dispensing device and a second wall portion of the discrete article dispensing device, wherein the first wall portion comprises a ramp that extends past the slot towards the discrete article transporting surface, the ramp having a drop-off end from which the discrete articles are deposited onto the discrete article transporting surface. The method further comprising determining, at the processing entity, at least in part on a basis of the characteristic associated with the at least one discrete article, a suitable distance between the drop-off end of the ramp and the discrete article transporting surface and causing the discrete article dispensing device to move in relation to the discrete article transporting surface for acquiring the suitable distance between the drop-off end of the ramp and the discrete article transporting surface.

In accordance with a seventh broad aspect, the present invention comprises a container filling machine for filling a plurality of containers with discrete articles. The container filling machine comprises a plurality of guiding paths between a discrete article dispensing device and at least one container to be filled. The container filling machine further comprises a path blocking device located along each of the plurality of guiding paths at a position prior to the at least one container to be filled. Each path blocking device is operative for acquiring a first position in which the path blocking device blocks a passage of discrete articles along a guiding path and a second position in which the path blocking device allows the passage of discrete articles along the guiding path. The movement of the path blocking device between the first position and the second position is controlled via a solenoid device.

DETAILED DESCRIPTION

Shown inFIG. 1is a front view of a container-filling machine10in accordance with a non-limiting example of implementation of the present invention. The container filling machine10is suitable for loading into containers discrete articles, such as discrete articles for personal treatment (e.g. pharmaceutical pills, cosmetic items, etc) or candies, nuts, or any other type of discrete article. As used herein, the term “discrete article for personal treatment” includes any type of pharmaceutical discrete article that may be ingested (such as pressed-powder or gel cap pills, among other possibilities) as well as any cosmetic item that may be applied to an external part of the body (such as moisturizer capsules, for example).

In the non-limiting embodiment shown, the container filling machine10includes a discrete article dispensing device12, guiding trays13a-13e, vibration trays14a-14e, a plurality of guiding paths16, a sensing device18, a rejection device20, a counting device22, a plurality of path blocking devices24, and a set of funnels26for guiding the discrete articles into respective containers30.

In use, the discrete articles travel through the container filling machine in order to be placed into one of the containers30. Initially, a load of discrete articles is placed within the discrete article dispensing device12, which then deposits the discrete articles onto the guiding trays13a-13e. The guiding trays13a-13emove the discrete articles forward via vibrational motion, and also cause the discrete articles to become spaced from one another as they travel towards the vibration trays14a-14e. Once the discrete articles reach the vibration trays14a-14e, the vibration trays14a-14econtinue to carry the discrete articles towards the guiding paths16and create further spacing between the discrete articles. The discrete articles then slide down the guiding paths16through the sensing device18, which senses whether or not the discrete articles are defective. The discrete articles then pass the rejection device20, which removes defective ones of the discrete articles from continued travel along the guiding paths16. If not removed by the rejection device20, the discrete articles continue to pass through the counting device22. The counting device22counts the discrete articles before they enter the funnels26which funnel the discrete articles into one of the containers30. The sensing device18, rejection device20, counting device22and plurality of path blocking devices24are described in more detail in issued U.S. Pat. No. 7,956,623, belonging to the same applicant, and as such will not be described in more detail herein.

Shown inFIGS. 2A and 2Bare cross-sectional side views of an upper portion of the container filling machine10. These figures show side views of the discrete article dispensing device12and the vibration tray14ein two different positions, which will be described in more detail further on in the description.

The Discrete Article Dispensing Device12

The discrete article dispensing device12comprises a receptacle30for holding a load of discrete articles40that are to fill the containers30. The load of discrete articles40is generally placed into the receptacle30through an opening32in the discrete article dispensing device12. The discrete articles do not need to be provided to the discrete article dispensing device12in any particular order or orientation, and as such may be quickly poured into the hopper12. In use, the opening32may be left open to the environment, or may be covered by a lid or other form of cover (not shown). The lid may be permanently attached to the receptacle, such that it may be opened and closed via a hinge-type mechanism, or alternatively, the lid may be a separate component from the receptacle30that may be removably secured over the opening32to the receptacle30via a friction fit or snap-fit arrangement, among other possibilities.

The load of discrete articles40may be placed inside the receptacle30in any suitable manner, such as by dumping or pouring the load of discrete articles40through the opening32into the receptacle30. The load of discrete articles40may be placed into the receptacle30either manually by a worker operating the container filling machine10, or by another machine or robot that is capable of continually or repetitively filing the receptacle30with discrete articles.

The receptacle30according to the present invention may be of any size and shape. In the non-limiting example shown inFIGS. 1, 2A and 2B, the receptacle30is in the shape of a rectangular trough with two side walls36a,36h, two end walls38a,38b(shown inFIG. 1) and a base portion34that comprises a dispensing outlet42through which the discrete articles exit the receptacle30. It should, however, be understood that the receptacle30may be of any other shape and size, such as cylindrical or cone-shaped, no long as it is able to hold the load of discrete articles40. In accordance with a non-limiting example, the receptacle30has a shape and size suitable for accommodating a load of discrete articles having a weight of between 10 kg to 30 kg and a volume of between 15 L to 75 L. In a specific, non-limiting example, the receptacle30has a volume of approximately 60 L and is able to support at least a weight of 21 kg worth of discrete articles. The receptacle30may be made of any suitable material known in the art, such as plastic, ceramic and/or stainless steel, among other possibilities.

In the non-limiting embodiment shown, the base portion34of the receptacle30comprises a first bottom wall44a, a second bottom wall44band a dispensing outlet42. The dispensing outlet42comprises a slot46that is formed between the first wall portion44aand the second wall portion44b, for allowing discrete articles to exit the receptacle30, and a ramp portion48for receiving the discrete articles from the slot46and transporting them onto the guiding trays13a-13d. The slot46may extend the entire length of the base portion34, or may extend only along a portion of the length of the base portion34, such as along 60% or 70% of the length, for example.

In addition, and although not shown in the Figures, the slot46may have a gate portion or other slot narrowing device, such that the output through which the discrete articles exit the discrete article dispensing device12onto the guiding trays13a-13emay be adjusted in size. For example, the adjustable gate portion may adjust the size of the output to make it smaller or larger in order to facilitate the depositing of discrete articles of different sizes onto the guiding trays13a-13e.

In the non-limiting embodiment shown inFIG. 1, the container filling machine12comprises five guiding trays13a-13eand five respective vibration imparting devices84for imparting vibrational motion to the guiding trays13a-13e. Each of the guiding trays13a-13eis in communication with its own vibration imparting device84such that the vibrational motion of each guiding tray13a-13emay be controlled independently. These vibration imparting devices84may comprise either electromagnetic drive units, pneumatic drive units or mechanical drive units, among other possibilities, that are attached to spring systems (not shown), and/or resilient plates (not shown) for transmitting vibrational motion to the guiding trays13a-13e. Although five guiding trays13a-13eare shown, it should be understood that any number of guiding trays could be used in order to form the initial discrete article transporting surface that receives the discrete articles from the discrete article dispensing device12.

As mentioned above, the dispensing outlet42further comprises a ramp portion48that extends past the slot46for receiving the discrete articles that exit through the slot46and directing them downwards towards the guiding paths13a-13e. In the embodiment shown inFIGS. 2A and 2B, the ramp portion48is formed by the first bottom wall44aand extends from the slot46towards the guiding paths13a-13e. In addition, the ramp portion48of the first bottom wall44aunderlaps the second bottom wall44b, such that the ramp portion48is positioned underneath the second bottom wall44b.

The ramp portion48may have any suitable slope for enabling discrete articles from the load of discrete articles40to slide down and be deposited onto the guiding trays13a-13e. For example, the ramp portion48may have a slope of between 10-20 degrees, when measured from a horizontal plane. In a non-limiting example of implementation, the ramp portion48for discharging the discrete articles has a slope of approximately 15 degrees when measured from a horizontal plane. It should be appreciated that these angles are given for the purpose of example, and should not be used to limit the present invention.

The base portion34of the receptacle30may have a variety of different configurations. In the embodiment shown inFIGS. 2A and 2B, the first bottom wall44aand the second bottom wall44bof the base portion34define sloped surfaces that extend respectively from the two side walls36a,36btowards each other, such that the slot46is located in proximity to the center of the width of the receptacle30and the ramp portion48formed by the first bottom wall44aextends underneath the second bottom wall44b. However, other configurations for the base portion34of the receptacle30are also possible without departing from the scope of the present invention.

Shown inFIGS. 3A-3Bare three alternative configurations for the base portion34of the receptacle30. Each configuration comprises a dispensing outlet42in accordance with the present invention. Like reference numerals have been used to represent like parts.FIG. 3Ashows a first alternative embodiment of a base portion34, wherein the bottom walls are integrally formed with the side walls36a,36bof the receptacle30. As such, the base portion34of the receptacle30is formed by the two side walls36a,36b. The side wall36aforms the ramp portion48that extends past the slot46and underlaps the side wall36bfor receiving the discrete articles from the slot46and directing them towards the guiding trays13a-13e. In the second alternative embodiment shown inFIG. 3B, the second bottom wall44bforms a sloped surface that extends from the side wall36balmost all the way to the interior of the opposing side wall36a, such that the slot46that is defined between the first bottom wall44aand the second bottom wall44bis located towards one side of the receptacle30. The first bottom wall44aunderlaps the second bottom wall44bsuch that a majority of the first bottom wall44aforms the ramp portion48that extends past the slot46towards the guiding paths13e. In the third alternative embodiment shown inFIG. 3C, the base portion34does not comprise a second bottom wall, and instead comprises only a first bottom wall44a. In this embodiment, the first bottom wall44aforms a sloped surface that extends downwards from the side wall36ain the direction of the side wall36b. The slot46is thus formed beneath the side wall36band the first bottom wall44a. The first bottom wall44athen continues past the slot46for forming the ramp portion48that receives the discrete articles from the slot and guides them downwardly towards the guiding paths13a-13. Although in the embodiments described above it is the first bottom wall44a(or the side wall36a) that forms the ramp portion48that extends past the slot46, it should be understood that in alternative embodiments, it is the second bottom wall44bthat forms the ramp portion48for receiving the discrete articles from the slot46.

In existing discrete article dispensing devices, the slot through which the discrete articles exit the device opens directly onto the discrete article transporting surface. As a result, as the discrete articles exit the slots onto the transporting surface, they have the entire weight of the load of discrete articles sitting on top of them. This weight is in turn transferred to the discrete article transporting surface onto which they are being dispensed.

In accordance with the present invention, the base portion34of the receptacle is designed so as to support the bulk of the weight of the load of discrete articles40as discrete articles exit through the slot46. In this manner, the weight of the load of discrete articles40is not transferred to the discrete article transporting surface, which in the embodiment shown in the Figures, comprises the guiding trays13a-13e. As described above, in accordance with the present invention, the dispensing outlet42comprises both a slot46through which the discrete articles exit, and a ramp portion48that extends from the slot for receiving the discrete articles from the load of discrete articles40as they travel pass through the slot46. Given that the discrete articles do not fall directly from the slot46onto the guiding trays13a-13e, the weight of the load of discrete articles40is not transferred to the guiding trays13a-13e. Instead, at least part of the base portion34of the receptacle30supports the bulk of the weight of the load of discrete articles40. More specifically, at least one of the first wall bottom wall44aand the second bottom wall44bsupports the weight of the load of discrete articles40.

In the embodiment shown inFIGS. 2A and 2B, the weight of the load of discrete articles40is supported by the first bottom wall44aand the second bottom wall44b. As discrete articles from the load of discrete articles40exit the slot46, the ramp portion48supports the weight of the discrete articles that have exited the slot46, such that the guiding trays13a-13e(that make up the discrete article transporting surface), only support the weight of the discrete articles that are positioned on the guiding trays13a-13e. However, in alternative embodiments, such as those shown inFIGS. 3band 3c, the weight of the load of discrete articles40is supported differently. For example, in the case of the receptacle30shown inFIG. 3b, it is the second bottom wall44b, that will support the majority of the weight of the load of discrete articles40, and in the case of the receptacle30shown inFIG. 3c, it is the first bottom wall44athat supports the majority of the weight of the load of discrete articles40.

Although not shown in the Figures, the discrete article dispensing device12may be mounted to, or in relation to, the container filling machine10in a variety of different manners. Referring back toFIG. 1, the discrete article dispensing device12may be mounted to a frame of the container filling machine10via connector elements50that connect the side walls38a,38bof the discrete article dispensing device12to the frame for supporting the receptacle30over the guiding trays13a-13e. Alternatively, the connector elements50may be connected to the discrete article dispensing device12at other positions along the outer surface of the device12. The connector elements50may be plates or rods that connect the discrete article dispensing device12to the frame of the container filling machine10in a fixed position, or the connector elements50may be adjustable components that enable the position of the discrete article dispensing device12to be adjusted in relation to the frame of the container filling machine10, and more specifically, in relation to the receiving surface of the guiding trays13a-13e(or other form of discrete article transporting surface).

For example, the adjustable connector elements50may be hydraulic or pneumatic pistons that are able to expand and retract for increasing or decreasing the height of the discrete article dispensing device12in relation to the receiving surface of the guiding trays13a-13e. The adjustable connector elements50could also be mechanical connector elements50, such as a ratcheted connector or a rack and pinion gear arrangement, among other possibilities, that is capable of mechanically adjusting the height of the discrete article dispensing device12in relation to the receiving surface of the guiding trays13a-13e. The adjustment of the height of the discrete article dispensing device12may be done manually, or alternatively may be automated such that a drive mechanism in communication with the connector elements50causes the height to be adjusted. When automated, this adjustment may be performed on a basis of user input information or an input received from a sensor, which will be described in more detail below.

As shown inFIGS. 2A and 2B, in use, the discrete articles are deposited from the ramp portion48of the discrete article dispensing device12onto a back end of the guiding trays13a-13e. Due to the vibrational motion applied to the guiding trays13a-13e, the discrete articles are caused to move towards the front of the guiding trays13a-13esuch that they are able to move onto vibration trays14a-14e. However, in the embodiments shown, in order to move from the back of the guiding trays13a-13etowards the front of the guiding trays13a-13e, the discrete article must pass by the drop-off edge50of the ramp portion48. The drop-off edge50of the ramp portion48thus acts as a type of gate under which the discrete articles may pass. The height between the receiving surface of the guiding trays13a-13eand the drop-off edge50of the ramp portion48therefore acts to limit the amount of discrete articles that may move past the drop-off edge50of the discrete article dispensing device12.

InFIG. 2A, the drop-off edge50of the discrete article dispensing device12is positioned at a height “h1” above the receiving surface of the guiding trays13a-13e. At height “h1” only a single layer of discrete articles is able to pass beneath the drop-off edge50of the discrete article dispensing device12at the same time. This helps to prevent too many discrete articles from arriving at the vibration trays14a-14eat the same time. InFIG. 2B, the drop-off edge50is positioned at a height of “h2” above the receiving surface of the guiding trays13a-13e. At height “h2”, at least two stacked layers of discrete articles are able to pass by the drop-off edge50of the discrete article dispensing device12. In this manner, the discrete article dispensing device12allows a greater amount of discrete articles to move towards the vibration trays14a-14eat the same time.

In the case where the container filling machine10is intended to be used to process discrete articles of different sizes and shapes, it makes sense for the positioning of the discrete article dispensing device12to be adjustable in relation to the receiving surface of the guiding trays13a-13e. As mentioned above, the adjustment of the height of the discrete article dispensing device12in relation to the receiving surface of the guiding trays13a-13emay be done manually or may be automated via a dispensing device drive mechanism that causes the height to be adjusted. The dispensing device drive mechanisms generally comprises an electrical motor in communication with mechanical components, such as a gear assembly or a piston assembly, for causing the height of discrete article dispensing device12to be adjustable.

The manner in which the height of the discrete article dispensing device12may be adjusted will now be described in more detail with respect to the block diagram ofFIG. 4and the flow diagram ofFIG. 5. As shown inFIG. 4, a control entity60is in communication with the dispensing device drive mechanism74that is operative for causing the position of the discrete article dispensing device12to be adjusted. As described above, the dispensing device drive mechanism74generally comprises an electrical motor in order to impart motion to mechanical components that cause the receptacle30of the discrete article dispensing device12to move up and down.

In accordance with the non-limiting embodiment shown, the control entity60comprises an input62for receiving commands and/or information from a user interface76and/or a sensor72(optional). The control entity60further comprises a processing entity64in communication with a memory66. The memory comprises data68and program instruction70for being accessed and executed by the processing entity64for implementing the functionality that will be described in more detail below.

The control entity60may be a dedicated control entity for controlling the movement of the discrete article dispensing device12, or alternatively, the control entity60may be in communication with other components, such as a tray supporting drive mechanism80and a vibration imparting device82, which will be described in more detail below, for controlling the functionality of these components as well. The control entity60may be an integral part of the container filling machine10, or may be a portable device such as a laptop, or desktop computer that is connected via cables to the components74,80and82. In yet a further alternative embodiment, the control entity60may be implemented within a portable wireless device, such as a smart phone, such that it is in communication with the various components over wireless RE or cellular connections. In yet a further example of implementation, the control entity60may be implemented at a remote server, such that it is in communication with the components72,74,76,80and82over network connections, via the internet, or a local intranet, for example.

In accordance with a first non-limiting example of implementation, the control entity60is operative for controlling the movement of the dispensing device drive mechanism74at least in part on a basis of information entered by a user via the user interface76. In accordance with a second non-limiting example of implementation, the control entity60is operative for controlling the movement of the dispensing device drive mechanism74at least in part on a basis of information received from a sensor72. Each of these different scenarios will be described in more detail below.

i) Controlling Movement of the Dispensing Device Drive Mechanism74on a Basis of Information Entered by a User.

As mentioned above, the user interface76comprises user operable inputs78for enabling a user to provide information, such as commands, to the control entity60. The user operable inputs78may be buttons, levers, toggles or any other sort of mechanical input operable by a user and known in the art. The user interface76may also be a graphical user interface that comprises a display screen84. In the case of a graphical user interface, the user operable inputs78may include user input elements displayed on the display screen that operable by “clicking” on the user input elements via an input device such as a mouse, a stylus pen, a touch sensitive screen or a ball mechanism.

The control entity60may receive information from a user via the user interface76indicative of one or more command signals for causing the control entity60to cause an adjustment in the position of the discrete article dispensing device12. For example, a user may operate one or more of the user operable inputs78in order to provide a command signal to the control entity60, indicative that the discrete article dispensing device12should be moved “up” or “down”. This may be done by pushing an up/down lever into an “up” position, for providing a signal indicative that the discrete article dispensing device should move upwards so as to increase the height between the discrete article dispensing device12and the receiving surface of the guiding trays13a-13e. So long as the user is activating the user operable input to provide an “up” command signal, or until a user provides a “stop” command signal, the processing entity64will issue control signals to the dispensing device drive mechanism74, for causing the discrete article dispensing device12to move upwards. Similarly, a user may operate one or more of the user operable inputs78in order to provide a signal to the control entity60indicative that the discrete article dispensing device should move downwards. So long as the user is activating a “down” user operable input, or until a user stops the downwards movement by providing a “stop” input, the processing entity64will issue control signals to the dispensing device drive mechanism74, for causing the discrete article dispensing device12to move downwards, thereby decreasing the height between the discrete article dispensing device12and the receiving surface of the guiding trays13a-13e.

In the above manner, a user may interact with the user interface76in order to position the discrete article dispensing device12at a desired height in relation to the receiving surface of the guiding trays13a-13e. A desirable height at which the discrete article dispensing device12may be positioned above the receiving surface of the guiding trays13a-13ewould be known by a person of skill in the art, and may be based, at least in part, upon criteria such as the size and shape of the discrete articles being handled, the frequency of vibration of the guiding trays and the rate at which the discrete article dispensing device12supplies discrete articles from the load of discrete articles40to the guiding trays13a-13e.

Alternatively, the control entity60may receive information from a user via the user interface76indicative of a characteristic associated with at least one discrete article from the load of discrete articles40being handled, and cause the position of the discrete article dispensing device12to be adjusted on a basis of this received information. The manner in which this is done will be described in more detail with reference to the flow chart ofFIG. 5.

At step100, the control entity60receives from a user, information indicative of a characteristic of at least one discrete article from the load of discrete articles40being handled. The characteristic may be indicative of an identifier of the discrete articles, such as the name of the discrete article, a serial number associated with the discrete article or, in the case where the discrete articles are pharmaceutical pills, the generic chemical compound of the pills. The characteristic could also be the weight of an individual discrete article, the volume of an individual discrete article, the diameter of an individual discrete article or any other physical characteristic of a discrete article. The characteristic could also be associated with the entire load of discrete articles40being handled, such as the weight of the load of discrete articles40, the volume of the load of discrete articles40or a batch number of the load of discrete articles. This information indicative of the characteristic is received at the input62from the user interface76, and is then passed to the processing entity64.

At step102, the processing entity64may then determine, at least in part on a basis of the information indicative of a characteristic of at least one discrete article, a suitable height between the drop-off end50of the discrete article dispensing device12and the receiving surface of the guiding trays13a-13e, at which to position the discrete article dispensing device12. This determination may be done in a variety of manners. For example, the determination may be done on a basis of a look-up function using a database that is stored in the data68of the memory66. The database may comprise a list of characteristics that could be provided by a user, and associated with each characteristic is a corresponding height for the discrete article dispensing device12. For example, in the case where the information indicative of a characteristic of at least one discrete article is a name or other identifier of the discrete articles, the processing entity64may access the database and look for an entry that matches the characteristic identified by the user. Once the processing entity64has found the entry in the database that matches the information indicative of a characteristic input by the user, the processing entity64would then determine the corresponding height for the discrete article dispensing device12that is contained in the entry for the matching characteristic.

The database may be provided by a manufacturer of the container filling machine10, or may be slowly established by a user of the container filling machine. For example, each time a user has manually and possibly through trial-and-error established a suitable position for the discrete article dispensing device12when handling a given type of discrete article, the user may save a record within the memory66in order to store in connection with one or more characteristics of the discrete article (such as its weight, shape, volume, name and/or serial number) an associated position wherein the drop-off end50of the discrete article dispensing device12is at a suitable height from the receiving surface of the guiding trays13a-13e.

Alternatively, the determination of a suitable height may be done by executing a pre-established algorithm. The pre-established algorithm may be stored within the program instructions70of the memory66. For example, in the case where the information indicative of a characteristic of at least one discrete article is a weight or volume of a discrete article, the processing entity64may access the pre-established algorithm stored in the memory, for applying the entered weight or volume into the pre-established algorithm. By running the algorithm at least in part on a basis of the entered characteristic (such as weight or volume), the output of the algorithm will provide a suitable position for the discrete article dispensing device12. In order to obtain the output of the algorithm, other values may need to be input into the algorithm, such as the frequency of vibration of the guiding trays13a-13eand the size of the slot46, among other possibilities.

Once a suitable position for the discrete article dispensing device12has been determined, at step104, the processing entity64is operative for causing the discrete article dispensing device to acquire the suitable position. This may be done by issuing one or more control signals to the dispensing device drive mechanism74, for instructing the discrete article drive mechanism74to move the discrete article dispensing device12up or down, until the suitable position has been acquired wherein the drop off end50of the discrete article dispensing device12is at the desired height above the receiving surface of the guiding trays13a-13e.

ii) Controlling Movement of the Dispensing Device Drive Mechanism74on a Basis of Information Received from a Sensor.

In accordance with a second non-limiting example of implementation, the control entity60is operative for controlling the movement of the dispensing device drive mechanism74at least in part on a basis of information received from a sensor72.

The sensor72(which may include one or more sensors) may be a capacitive sensor or an optical sensor that is operative for detecting at least one of a volume or a weight of at least one of the discrete articles of the load of discrete articles40. Different types of sensors operative for obtaining readings of volume and/or weight are known in the art, and as such will not be described in more detail herein. The sensor72may be positioned either in proximity to the opening32of the receptacle30for obtaining sensor readings as the load of discrete articles40is being supplied to the receptacle30. Or the sensor72may be positioned in proximity to the slot46for obtaining sensor readings as discrete articles exit the receptacle30. These sensor readings that are obtained by the sensors72are indicative of a characteristic of at least one of the discrete articles of the load of discrete articles40.

The sensor72may also be a scale that is operative for obtaining a reading of the weight of the receptacle. In this manner, the sensor72may take a reading of the weight of the receptacle after an initial load of discrete article40has been placed within the receptacle30. As mentioned previously, the weight of a pre-established load of discrete articles (such as 10,000 discrete articles) may be considered as a characteristic of at least one of the discrete articles of the load of discrete articles40.

Any sensor72that is operative for obtaining a reading indicative of a characteristic of at least one of the discrete articles of the load of discrete article40is included within the present invention. These sensor readings that are indicative of a characteristic of at least one of the discrete articles are passed from the sensor72to the input62of the control entity60, which are in turn passed to the processing entity64. The processing entity is then operative for processing the information indicative of the characteristic of at least one of the discrete articles in the same manner as described above with respect to steps102and104, for causing the discrete article dispensing device to acquire the suitable position for the given type of discrete articles being processed.

The Vibration Trays14a-14e

As described above, the discrete article dispensing device12is operative for receiving an initial load of discrete articles, and for releasing those discrete articles onto the guiding trays13a-13e, which in turn, supply those discrete articles onto the vibration trays14a-14e.

In the non-limiting embodiment shown inFIG. 1, the container-filling machine10of the present invention includes five vibration trays14a-14e, with one guiding tray and one vibration tray for each of the containers30to be filled. Positioned beneath the vibration trays14a-14eare vibration imparting devices82for imparting vibrational motion to the vibration trays14a-14e. Although not shown inFIGS. 2A and 2B, there are a total of five vibration imparting devices82, with one vibration imparting device82positioned beneath each one of the five vibration trays14a-14erespectively. Each of the vibration trays14a-14eis in communication with its own vibration imparting device82such that the vibrational motion of each vibration tray14a-14emay be controlled independently. These vibration imparting devices82may comprise either electromagnetic drive units, pneumatic drive units or mechanical drive units, among other possibilities, that are attached to spring systems (not shown), and/or resilient plates (not shown) for transmitting vibrational motion to the vibration trays14a-14e. The control of this vibrational motion will be described in more detail below.

Shown inFIG. 2Ais a side view of vibration tray14eand shown inFIG. 6is an exploded perspective view of the vibration trays14a-e. In examples shown, each vibration tray14a-ecomprises four channels90for transporting discrete articles towards the guiding paths16. The four channels90are each substantially V-shaped. However, other shapes of channels are also included within the scope of the present invention. For example, the channels90may be U shaped, or have flat bottoms, among other possibilities.

In accordance with an optional embodiment, each of the channels90includes a wall-portion (not shown) that extends along a longitudinal length of the channel90for dividing the channel90into a first side and a second side. As such, the wall portion creates two discrete article receiving paths within each channel90. A more detailed description of vibration trays that comprise wall portions for dividing each channel may be found in U.S. Patent Publication 2009/0255948.

Given that each of the five vibration trays14a-14eincludes four channels90, the container filling machine10comprises a total of twenty channels90, with each channel90leading into a respective one of the guiding paths16. As such, in the non-limiting embodiment shown, there is a one-to-one ratio between channels90and guiding paths16. It should, however, be appreciated that in an alternative embodiment, each of the vibration trays14a-14ecould include any number of channels90without departing from the spirit of the invention. In addition, two or more of the channels90could supply discrete articles to a single guiding path16. As such, it is not required that there is a one-to-one ratio between channels90to guiding paths16.

Each of the vibration trays14a-14ecomprises a discrete article receiving end92, and a discrete article drop-off end94. The discrete article receiving ends92receive the discrete articles from the guiding trays13a-13e(or directly from the discrete article dispensing device12in the case where guiding trays13a-13eare not included). Once received, the discrete articles travel along the channels90of the vibration trays14a-14etowards the discrete article drop-off ends94. The discrete articles are then provided to the guiding paths16of the container filling machine10from the discrete article drop-off ends94. Through the vibrational motion of the vibration trays14a-14e, the discrete articles are caused to travel along the channels90from the discrete article receiving ends92to the discrete article drop-off ends94. By adjusting the slope of the vibration trays14a-14e, the speed at which different types of discrete articles travel along the channels90may be adjusted. For example, by increasing the slope of the vibration trays14a-14e, the speed at which a given type of discrete article travels along the channels90also increases. Therefore, in order to obtain a desired speed at which a given type of discrete article travels from the discrete article receiving end92to the discrete article drop-off end94, the slope of the vibration trays14a-14emay be adjusted.

In use, the vibration trays14a-14eare positioned with a downward incline or slope towards the guiding pathways16. In the non-limiting example shown inFIG. 2A, the vibration trays14a-14ehave a relatively small slope, whereas in the non-limiting example shown inFIG. 2B, the vibration trays14a-14ehave been adjusted to acquire a much steeper slope. In general, the greater this incline or slope, the faster a common type of discrete article will travel from the discrete article receiving end92towards the discrete article drop-off end94.

In order to be supported between the discrete article dispensing device12and the guiding paths16, the vibration trays14a-14eare connected to one or more tray supporting frames96. The tray supporting frames96support the vibration trays14a-14eand allow the slope of the trays14a-14eto be adjusted. In the embodiment shown inFIGS. 2A, 2B and 6, the five vibration trays14a-14eare all supported by the same tray supporting frame96. However, in alternative embodiments, each of the vibration trays14a-14emay be supported by a separate supporting frame96, such that the slope of each vibration tray may be adjusted individually.

In the embodiment shown, the vibration trays14a-14eall sit on a common plate97that it connected to the tray supporting frame96at three positions, as will be described below. The vibration trays14a-14emay be affixed to the plate97via any manner known in the art, such as via bolts, some other form of mechanical fastener or adhesives, among other possibilities. The tray supporting frame96comprises a first portion96athat comprises a pivot axis98. The common plate97is connected at either end of the pivot axis98via two connecting plates95. As such, the plate97that supports the vibration trays14a-14eis adjustable about the pivot axis98such that the slope of the vibration trays14a-14emay be adjusted. Accordingly, the pivot axis98is substantially perpendicular to the longitudinal axes of the channels90along which the discrete articles travel.

In the non-limiting embodiment shown inFIGS. 2A and 2B, the pivot axis98of the tray supporting frame96is positioned towards the front of the vibration trays14a-14e, such that it is in proximity to the drop-off ends94of the vibration trays14a-14e. It should, however, be appreciated that in alternative embodiments, the pivot axis98may be located anywhere along the length (from the discrete article receiving end92to the discrete article drop-off end94) of the vibration trays14a-14e.

The tray supporting frame96further comprises a second component96bthat supports the vibration trays14a-14eand causes the vibration trays14a-14eto be adjustable about the pivot axis98. The second component96bis operative for causing the position of the vibration trays14a-14eto be adjusted and for holding the vibration trays14a-14ein multiple different positions such that the vibration trays14a-14eare able to provide different slopes to the discrete articles that are filling the containers30.

In a first non-limiting example, the vibration trays14a-14eare manually adjustable about the pivot axis98for changing the slope provided by the vibration trays14a-14b. In such a circumstance, the second component96bmay comprise a variety of different slots for receiving an associated pin attached to the vibration trays14a-14e, such that when the pin is positioned within a different slot, the vibration trays14a-14eare positioned to provide a different slope. Any other mechanical supporting structure that would allow a user to manually adjust the slope provided by the vibration trays14a-14eis also included within the scope of the present invention. For example, a manually rotatable rack and pinion gear arrangement that is able to provide translational motion could be used.

In a second non-limiting example, which is shown in the Figures, the adjustment of the vibration trays14a-14emay be automated. In such an embodiment, the second component96bof the tray supporting frame96further comprises a tray supporting drive mechanism80that is operative for receiving command signals for causing one or all of the trays14a-14eto be adjusted about the pivot axis98for acquiring a new slope. More specifically, the tray supporting drive mechanism80is operative for tilting the vibration trays14a-14eabout the pivot axis98for causing the vibration trays14a-14eto acquire a new slope. The adjustment of the vibration trays14a-14emay be performed on a basis of user input information or an input received from a sensor, as will be described in more detail below.

The tray supporting drive mechanism80may be implemented in a variety of different manners. In accordance with a first non-limiting example, the tray supporting drive mechanism80comprises an electrical motor that is in communication with a mechanical gear arrangement102, as shown inFIG. 6. The mechanical gear arrangement102may comprise one or more rack and pinion gears, screw gears or helical gears for enabling an up-and-down movement that will cause one or more of the vibration trays14a-14eto tilt about the pivot axis98for acquiring a new slope. In a second non-limiting example, the tray supporting drive mechanism80comprises one or more hydraulic or pneumatic cylinders together with pump actuators for causing the cylinders to expand and contract in order to adjust the tilt of the vibration trays14a-14eabout the pivot axis98.

In the non-limiting embodiment shown, the plate97that supports the vibration trays14a-14eis connected to the tray supporting frame96at three locations. Namely, on either side of the pivot axis98and at a third location that is in communication with the tray supporting drive mechanism80. For example, the plate97is connected to the motorized drive mechanism80, such that when the drive mechanism80is activated, the plate97, which supports the vibration trays14a-14e, pivots about the pivot axis98. The drive mechanism80may include a motorized adjustment screw that is mounted to a shaft that is in contact with the plate97at a mid-point of the plate97, or at multiple points along the length of the plate97. In order for the motor to overcome relatively significant friction, a gearbox having a ratio of 80:1 to 120:1 may be used.

In the case where the container filling machine10is intended to be used to process discrete articles of different sizes and shapes, it makes sense for the slope of the vibration trays14a-14eto be adjustable, so as to better control the speed at which the container filling machine10is able to fill the containers30. At a given slope, discrete articles of a relatively small size may move at a reasonably good speed, but at that same slope, discrete articles having a larger size may not move fast enough. Therefore, in order to increase the speed of these larger size discrete articles, the slope of the vibration trays14a-14ecan be increased. In this manner, by adjusting the slope of the vibration trays14a-14e, the desired speed at which different types of discrete articles are handled can be better controlled. As mentioned above, the adjustment of the slope of the vibration trays14a-14bmay be done manually or may be automated via a tray supporting drive mechanism80that causes the slope to be adjusted.

The manner in which the slope of the vibration trays14a-14emay be adjusted will now be described in more detail with respect to the block diagram ofFIG. 4and the flow diagram ofFIG. 7. As shown inFIG. 4, a control entity60is in communication with the tray supporting drive mechanism80that is operative for causing the slope of the vibration trays14a-14eto be adjusted. As described above, the tray supporting drive mechanism80generally comprises an electrical motor in order to impart motion to mechanical components that cause the vibration trays14a-14eto tilt about the pivot axis98for adjusting the slope provided by the vibration trays14a-14e.

As mentioned previously, the control entity60comprises an input62for receiving commands and/or information from a user interface76and/or a sensor72(optional). The control entity60further comprises a processing entity64in communication with a memory66. The memory comprises data68and program instruction70for being accessed and executed by the processing entity64for implementing the functionality that will be described in more detail below.

The control entity60may be a dedicated control entity for controlling the movement of the vibration trays14a-14evia the tray supporting drive mechanism80, or alternatively, the control entity60may be in communication with other components, such as the dispensing device drive mechanism74, as described above, for controlling the functionality of these components as well.

In accordance with a first non-limiting example of implementation, the control entity60is operative for controlling the movement of the tray supporting drive mechanism80at least in part on a basis of information entered by a user via the user interface76. In accordance with a second non-limiting example of implementation, the control entity60is operative for controlling the movement of the tray supporting drive mechanism80at least in part on a basis of information received from a sensor72. Each of these different scenarios will be described in more detail below.

i) Controlling Movement of the Tray Supporting Drive Mechanism80on a Basis of Information Entered by a User.

As previously mentioned, the user interface76comprises user operable inputs78for enabling a user to provide information, such as commands, to the control entity60. The user operable inputs78may be buttons, levers, toggles or any other sort of mechanical input operable by a user and known in the art. The user interface76may also be a graphical user interface that comprises a display screen84. In the case of a graphical user interface, the user operable inputs78may include user input elements displayed on the display screen that are operable by “clicking” on the user input elements via an input device such as a mouse, a stylus pen, a touch sensitive screen or a ball mechanism.

The control entity60may receive information from a user via the user interface76indicative of one or more command signals for causing the control entity60to cause an adjustment in the slope of the vibration trays14a-14e. For example, a user may operate one or more of the user operable inputs78in order to provide a command signal to the control entity60, indicative that the slope of the vibration trays14a-14eshould be increased. This may be done by pushing an up/down lever into an “up” position, for providing a signal indicative that the vibration trays14a-14eshould tilt upwards so as to increase their slope. So long as the user is activating the user operable input to provide an “up” command signal, or until a user provides a “stop” command signal, the processing entity64will issue control signals to the tray supporting drive mechanism80, for causing the vibration trays14a-14eto tilt upwardly to increase the slope. Similarly, a user may operate one or more of the user operable inputs78in order to provide a signal indicative that the slope of the vibration trays14a-14eshould be decreased. So long as the user is activating a “down” user operable input, or until a user stops the downwards movement by providing a “stop” input, the processing entity64will issue control signals to the tray supporting drive mechanism80, for causing the vibration trays14a-14eto tilt downwardly to decrease their slope.

In an alternative embodiment, a user may enter, via the user interface76, an indication of a desired slope at which the vibration trays14a-14eshould be positioned. This may be done by using a keypad in order to enter a slope angle such as 30°. Upon receipt of this input angle, the control entity60may issue a signal to the tray supporting drive mechanism80instructing the tray supporting drive mechanism80to cause the vibration trays14a-14eto acquire a slope wherein the vibration trays14a-14eare at a 30° angle in relation to a horizontal plane.

Regardless of the manner in which a user provides information for causing the control entity60to cause an adjustment in the slope of the vibration trays, the vibration trays14a-14emay be adjustable so as to acquire any slope between being substantially parallel to the ground and substantially perpendicular to the ground. However, in an alternative embodiment, the vibration trays14a-14emay be able to acquire only two or more pre-defined positions in which the vibration trays14a-14eprovide different pre-defined slopes. In such an embodiment, the user interface76may provide one or more user-operable inputs78suitable for causing the vibration trays14a-14eto acquire these pre-defined positions. For example, by actuating a “pre-set one” button, the vibration trays14a-14emay automatically acquire a first pre-defined position, and by actuating a “pre-set two” button, the vibration trays14a-14emay automatically acquire a second pre-defined position. Any number of predefined positions are possible. The pre-defined positions may be pre-programmed into the container filling machine by a manufacturer, be part of a software download, or may be programmable by a user of the container filling machine for establishing pre-defined “favorite” positions.

In the above manner, a user may interact with the user interface76in order to position the vibration trays14a-14eat a desired slope between the discrete article dispensing device12and the guiding paths16. A desirable slope for the vibration trays14a-14ewould be known by a person of skill in the art, and may be based, at least in part, upon criteria such as the size and shape of the discrete articles being handled, the frequency of vibration of the vibration trays14a-14eand the rate at which the discrete article dispensing device12supplies discrete articles to the guiding trays13a-13e, and in turn, the vibration trays14a-14e.

In accordance with a second non-limiting example, the control entity60may receive information from a user via the user interface76indicative of a characteristic associated with at least one discrete article from the load of discrete articles40being handled, and cause the position of the slope of the vibration trays14a-14eto be adjusted on a basis of that received information. The manner in which this is done will be described in more detail with reference to the flow chart ofFIG. 7.

At step110, the control entity60receives from a user, information indicative of a characteristic of at least one discrete article from the load of discrete articles40being handled. As previously indicated, the characteristic may be indicative of an identifier of the discrete articles, such as the name of the discrete article, a serial number associated with the discrete article or, in the case where the discrete articles are pharmaceutical pills, the generic chemical compound of the pills. The characteristic could also be the weight of an individual discrete article, the volume of an individual discrete article, the shape of an individual discrete article, the diameter of an individual discrete article or any other physical characteristic of a discrete article. The characteristic could also be associated with the entire load of discrete articles40being handled, such as the weight of the load of discrete articles40, the volume of the load of discrete articles40or a batch number of the load of discrete articles. This information indicative of a characteristic is received at the input62from the user interface76, and is then passed to the processing entity64.

At step112, the processing entity64may the determine, at least in part on a basis of the information indicative of a characteristic of at least one discrete article, a suitable slope for the vibration trays14a-14e. This determination may be done in a variety of manners. For example, the determination may be done on a basis of a look-up function using a database that is stored in the data68of the memory66. The database may comprise a list of characteristics that could be provided by a user, and associated with each characteristic is a corresponding slope for the vibration trays14a-14e. For example, in the case where the information indicative of a characteristic of at least one discrete article is a name or other identifier of the discrete articles, the processing entity64may access the database and look for an entry that matches the characteristic entered by the user. Once the processing entity64has found the entry in the database that matches the information indicative of a characteristic input by the user, the processing entity64would then determine the corresponding slope that is contained in the entry for the matching characteristic.

The database may be provided by a manufacturer of the container filling machine10, or may be slowly established/built by a user of the container filling machine10over time. For example, each time a user has determined (possibly through trial-and-error) a suitable slope for the vibration trays14a-14ewhen handling a given type of discrete article, the user may save a record within the memory66in order to store in connection with one or more characteristics of the discrete article (such as its weight, shape, volume, name and/or serial number) an associated slope for the vibration trays14a-14ewhen handling that given type of discrete article.

Alternatively, the determination of a suitable slope may be done by executing a pre-established algorithm. The pre-established algorithm may be stored within the program instructions70of the memory66. For example, in the case where the information indicative of a characteristic of at least one discrete article is a weight or volume of a discrete article, the processing entity64may access the pre-established algorithm stored in the memory, for applying the entered weight or volume into the pre-established algorithm. By running the algorithm at least in part on a basis of the entered characteristic (such as the weight or volume), the output of the algorithm may provide a suitable slope for the discrete article vibration trays14a-14e. In order to obtain the output of the algorithm, other values may need to be input into the algorithm, such as the frequency of vibration of the vibration trays14a-14eand the desired speed at which the containers are to be filled.

Once a suitable slope for the vibration trays14a-14ehas been determined, at step114, the processing entity64is operative for causing the tray supporting drive mechanism80to move the vibration trays14a-14einto the determined slope. This may be done by issuing one or more control signals to the tray supporting drive mechanism80, for instructing the tray supporting drive mechanism80to tilt the vibration trays14a-14eup or down, until the suitable slope has been acquired.

ii) Controlling Movement of the Tray Supporting Drive Mechanism80on a Basis of Information Received from a Sensor.

In accordance with a second non-limiting example of implementation, the control entity60is operative for controlling the movement of the tray supporting drive mechanism80at least in part on a basis of information received from a sensor72.

The sensor72(which may include one or more sensors) may be a capacitive sensor or an optical sensor that is operative for detecting at least one of a volume or a weight of at least one of the discrete articles of the load of discrete articles40. Different types of sensors operative for obtaining readings of volume and/or weight are known in the art, and as such will not be described in more detail herein. The sensor72may be positioned either in proximity to the opening32of the receptacle30for obtaining sensor readings as the load of discrete articles40is being supplied to the receptacle30. Or the sensor72may be positioned in proximity to the slot46for obtaining sensor readings as discrete articles exit the receptacle30. These sensor readings that are obtained by the sensors72are indicative of a characteristic of at least one of the discrete articles of the load of discrete articles40.

The sensor72may also be a scale that is operative for obtaining a reading of the weight of the load of discrete articles40that have been placed within the receptacle30. In this manner, the sensor72may take a reading of the weight of the receptacle30after an initial load of discrete article40has been placed within the receptacle30. As mentioned previously, the weight of a pre-established load of discrete articles (such as a load of 10,000 discrete articles) may be considered as a characteristic of at least one of the discrete articles of the load of discrete articles40.

Any sensor72that is operative for obtaining a reading indicative of a characteristic of at least one of the discrete articles of the load of discrete articles40is included within the present invention. These sensor readings that are indicative of a characteristic of at least one of the discrete articles are passed from the sensor72to the input62of the control entity60, which are in turn passed to the processing entity64. The processing entity is then operative for processing the information indicative of the characteristic of at least one of the discrete articles in the same manner as described above with respect to steps112and114, for causing the tray supporting drive mechanism80to cause the vibration trays14a-14eto acquire the determined slope.

With reference toFIGS. 2A and 2B, it can be seen that as the slope of the vibration trays14a-14eincrease, the height of the receiving ends92of these trays also increase in relation to the guiding trays13a-14e. As such, as the vibration trays14a-14eare caused to acquire a greater slope, the height of the guiding trays13a-13ealso needs to be increased such that the guiding trays13a-13eare still able to supply discrete articles from the discrete article dispensing device12to the vibration trays14a-14e. In addition, the guiding trays13a-13emay also need to be moved laterally forward towards the vibration trays14a-14e, so as to prevent a gap from being formed between the vibration trays14a-14eand the guiding trays13a-13e.

In order to adjust the height of the guiding trays13a-13e, the guiding trays may be positioned on a supporting stand108that is able to increase and decrease the height of the guiding trays13a-13e. The supporting stand108may include a mechanical rack and pinion gear arrangements, pneumatic or hydraulic pistons or any other mechanical device suitable for increasing the height of the guiding trays13a-13e. The height of the supporting stand108can be adjusted manually or can be automated.

In the case where the height adjustability of the supporting stand is automated, it is possible that the control entity60that adjusts the slope of the vibration trays14a-14eis able to simultaneously cause a drive mechanism to adjust the height of the guiding trays13a-13e. In accordance with a non-limiting embodiment, stored within the memory66are records in which an appropriate height for the guiding trays13a-13eis associated with each possible slope for the vibration trays14a-14e. As such, on the basis of a suitable slope for the vibration trays14a-14e, the guiding trays13a-13ecan be caused to acquire a corresponding suitable height.

The Path Blocking Device24

Once the discrete articles have left the vibration trays14a-14e, they continue travel along guiding paths16towards the containers30. The containers30are typically intended to be filled with a pre-determined number of discrete articles, such as 100 or 150 discrete articles, for example. As the discrete articles travel along the guiding paths16, they pass through a counting device22that counts the number of discrete articles that have passed there through. In this manner, once the counting device has detected a pre-determined number of discrete articles that have passed through one or more of the paths16leading to a given container30, one or more of the path blocking devices24located in a path16leading to that container30is caused to close, such that no further discrete articles pass by the closed path blocking devices24. In this manner, once a container has received the pre-determined number of discrete articles, no further discrete articles enter the container30until the filled container30has been moved out of the way, and a new container30has been moved into place.

As described above, multiple ones of the guiding paths16may lead into a single container30. In the non-limiting embodiment shown inFIG. 8, four guiding paths16lead into a funnel26that directs the discrete articles into a single container30. It should, however, be appreciated that any number of paths16could lead into any number of containers30, without departing from the spirit of the invention.

As mentioned above, prior to entering the containers30, the discrete articles pass through a counting device22. The purpose of the counting device22is to obtain a count of the discrete articles in order to ensure that the proper pre-determined number of discrete articles enter each container30. A more detailed discussion of a counting device22can be found in issued U.S. Pat. No. 7,956,623.

As shown inFIG. 8, the counting device22includes passageways122associated with each guiding path16, through which the discrete articles travel. Included within each passageway is circuitry for enabling the counting device to obtain a count of a discrete article passing there through. In addition, and as shown inFIG. 4, the counting device22is in communication with a processing entity64. The processing entity64may be part of a control entity60that controls the functionality of multiple components of the container filling machine10. However, in an alternative embodiment, the counting device22may be in communication with a processing entity that is dedicated to controlling the functionality of the counting device22.

In a non-limiting embodiment, the processing entity64is operative for simultaneously receiving and processing signals from the counting circuitry of each one of the passageways122of the counting device22. For example, in the case shown inFIG. 8, the processing entity64is operative to receive signals from four separate passageways122at approximately the same time. In such a case, the circuitry associated to each passageway16is operative for providing identification information to the processing entity64, such that the processing entity64is able to keep an appropriate count of the discrete articles for personal treatment passing through each respective passageway122of the counting device22.

The circuitry contained within each passageway122may be any suitable circuitry for detecting when a discrete article for personal treatment passes through the passageway91. For example, the counting device22may include optical circuitry or capacitance circuitry without departing from the spirit of the invention. Once the circuitry detects that an object, such as a discrete article, has passed through the passageway122, a signal is sent to the processing entity64, such that the processing entity64can keep a count of the number of discrete articles that have passed through each passageway122.

The purpose of the counting device22is to help control the number of discrete articles entering each container30.

As shown inFIG. 8, positioned between the counting device22and a container30are a plurality of path blocking devices24; namely one path blocking device24for each one of the guiding paths16. Each one of the guiding paths16then feeds into a funnel26which, in turn, leads into a container30.

In combination with the counting device22, the path blocking devices24are operative for controlling the number of discrete articles that enter each container30. More specifically, the path blocking devices24are operative to move between an open position and a closed position in order to either permit the travel of discrete articles into the container30or block the travel of discrete articles into the container30. In the embodiment shown inFIG. 8, the right-most path blocking device24is in a closed position, wherein the discrete articles travelling along that guiding path16are prevented from travelling into the container30. Whereas, the two middle path blocking devices24are in an open position, such that the discrete articles travelling along those guiding paths16are able to travel past the path blocking devices24into the container30.

Referring back toFIG. 4, the path blocking devices24are also in communication with the processing entity64, such that the processing entity64can control the movement of the path blocking devices24between the open position and the closed position. As shown inFIG. 4, the path blocking devices24are in communication with a processing entity64that is also in communication with the counting device22, as well as the other components in the container filling machine. It should be appreciated however that a processing entity64dedicated to the control of the path blocking devices24could also be used without departing from the spirit of the invention. In such a case, the processing entity64would be operative for receiving information from the counting device22indicative of a count of the number of discrete articles for personal treatment passing through respective passageways122.

In operation, the processing entity64controls the movement of the path blocking devices24at least in part on the basis of information received from the counting device22and the pre-determined number of discrete articles that are to be supplied to each container30. The information received from the counting device22is generally indicative of the number of discrete articles that has passed through each passageway122of the counting device22. The processing entity64processes this information in accordance with program instructions70stored in the memory66. Such program instructions may include a specific algorithm, such that the control of the path blocking devices24is performed in accordance with the specific algorithm. For example, the predefined algorithm may specify that once a pre-determined number of discrete articles has passed through a given guiding path16, the path blocking device24associated with that guiding path16is to be closed. For example, in the case where each container30is to be filled with one hundred discrete articles and there are four guiding paths16leading into each container30, the algorithm may specify that each path blocking device24is to be closed after twenty five discrete articles for personal treatment have passed by each path blocking device24. Alternatively, three of the path blocking devices24may close after twenty four discrete articles have passed along their respective guiding path16, and the fourth path blocking device24may close after twenty eight discrete articles have passed there through. In this way, the fourth path blocking device24is able to more precisely monitor the final discrete articles entering the container30. It should be appreciated that any algorithm suitable for controlling the number of discrete articles that enter each container30is included within the scope of the present invention and that a variety of different algorithms could be used in order to control the functioning of the path blocking devices24.

In the non-limiting embodiment shown inFIG. 8, the path blocking devices24are in the form of gates120that pivot about a pivot point124mounted to one side of the paths16. The gates120pivot about the pivot point124in order to move between the open position and the dosed position. In the closed position, the gates120form physical barriers that span across the width of a guiding path16. Whereas in the open position, the gates120are positioned along the sides of the guiding paths16such that discrete articles can pass by the gates120unobstructed and travel into a container30.

When in the closed position, the path blocking devices24are able to prevent discrete articles for personal treatment from continued travel into the funnels26while the filled containers30are being replaced with new containers30. Once a container30has been filled with the pre-determined number of discrete articles, all of the path blocking devices24that are positioned along the paths16that lead to that container30are closed such that the filled containers can be removed and replaced with new containers without stopping the flow of discrete articles through the counting device22of the container filling machine10. As such, the discrete articles simply accumulate at the path blocking devices24against the closed gates120. When the new containers30are in place underneath the funnels26, the path blocking devices24open, and the discrete articles for personal treatment that have accumulated at the gates120enter the new containers. In this manner, the flow of discrete articles for personal treatment does not slow down or stop for a container change.

In accordance with a non-limiting embodiment of the present invention, and as shown inFIG. 9, the gates120are controlled by solenoid devices126that convert electrical energy into mechanical energy. As shown, the gates120are connected to solenoid devices126via a rotating pin128. In the embodiment shown, the solenoid device128is a rotary solenoid. When electrical current is applied to, or cut from, the solenoid devices126, the solenoid devices126cause the rotation of the pin128that in turn causes the rotation of a respective gate120. As shown, a first end of the pin128is adapted for connection to the solenoid device126and a second end of the pin128is adapted for connection to a pivot axis of a gate120. The second end of the pin128may fit within the pivot axis124of the gate120via a friction fit or via projections that engage with a complimentary-shaped slot within the pivot axis. For example, the pin128may have a star-shaped end, or an X-shaped end, that fits within a complementary slot within the pivot axis124of the gate120. In this manner, as the pin128rotates, rotational motion is imparted to the gate120.

When electrical current is provided to the solenoid device126, the solenoid device126rotates the pin128, such that the gate120moves into the dosed position or the open position. When electrical current is cut from the solenoid device126, the pin128returns to its original neutral position (via a spring). In accordance with a non-limiting example of implementation of the present invention, when the solenoid device126is at a neutral position, such that no electrical current is applied thereto, the gate120is positioned in the middle of the pathway16, in this position, discrete articles are able to pass by the gate120, but the gate is not positioned up against the side wall of the path16providing a completely unobstructed path16. When the solenoid device126is activated by applying +5 Volts, the gate120moves approximately 22.5 degrees towards the opposite wall of the path16, such that the guiding path16is blocked. When −5 Volts is applied, the gate120opens approximately −22.5 degrees for causing the gate to open. Although certain voltage values and rotation angles have been provided in the above example, it should be appreciated that these values are provided for the sake of example only, and that the present invention is not limited to these values.

Accordingly, once the control entity64determines, based on information from the counting device22, that a pre-determined number of discrete articles has passed along a given one of the guiding paths16, the control entity64causes electrical current to be supplied to the solenoid device126of the gate120associated with that guiding path16, such that the gate120is able to acquire the closed position. Once all the gates120associated with a given container30have been closed (which means that the container has been filled with the pre-determined number of discrete articles) the filled container30is moved out of the way, and a new container30is moved into place. At that point, the control entity64applies electrical current to the solenoid devices126, such that the gates120open up again, and the discrete articles can flow into the new container30.

Using solenoid devices126to control the gates120prevents the use of air fluctuations, which would be required with pneumatic cylinders. In addition, solenoid devices126provide faster opening/closing than pneumatic cylinders. For example, a solenoid device can react in approximately 5 milliseconds, as opposed to the more typical 60 to 100 milliseconds required by a pneumatic cylinder. In addition, solenoid devices are often more durable and constant than pneumatic cylinders, and may also be cleaner as they do not necessarily require any oil or other lubrication.

In a preferred embodiment, the functionality of the components of the container filling machine10described above (i.e. the functionality of the discrete article dispensing device12, the guiding trays13a-13e, the vibration trays14a-14e, and the tray supporting drive mechanism80) are controlled via one or more computing units that include at least one software driven processing unit. However, in some embodiments of the invention, all or part of the functionality of these components may be implemented as pre-programmed hardware or firmware elements (e.g., application specific integrated circuits (ASICs), electrically erasable programmable read-only memories (EEPROMs), etc.) or other related components.

Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, variations and refinements are possible without departing from the spirit of the invention. Therefore, the scope of the invention should be limited only by the appended claims and their equivalents.