Rotary filling machine

A rotary filling machine includes a hub member and a hub insert. The hub member includes an internal bore defining an inner surface portion with a plurality of material transfer openings. The hub insert includes a portion disposed within the bore, wherein the portion includes an outer surface portion that includes a plurality of material transfer openings. One of the hub member or the hub insert is rotatable and the other of the hub member or the hub insert is stationary.

TECHNICAL FIELD

This application relates generally to filling machines, more specifically, to a rotary filling machine such as those used for filling bottles, cans or other containers with liquids or other flowable materials.

BACKGROUND

Rotary manifold filling machines commonly utilize a stationary flow divider plate atop a rotating filling head plate, with a bottom planar surface of the flow divider plate engaging an upper planar surface of the filling head plate. The flow divider plate includes multiple fill zone openings or recesses at the bottom surface and the filling head plate includes multiple fill ports at the upper surface. As the filling head plate rotates, the fill ports move sequentially into and out of alignment with the fill zone openings as containers are filled. Each fill port leads to a fill nozzle that aligns with the container opening for filling, with the container, nozzle and filling head plate rotating in a synchronous manner during fill. The plate against plate rotary filling arrangement can be difficult to seal effectively, and is also difficult to clean.

It would be desirable to provide a rotary filling machine capable of more effective sealing and/or reduced cleaning and maintenance.

SUMMARY

In one aspect, a rotary filling machine includes a hub member and a hub insert. The hub member includes an internal bore defining an inner surface portion with a plurality of material transfer openings. The hub insert includes a portion disposed within the bore, wherein the portion includes an outer surface portion that includes a plurality of material transfer openings. One of the hub member or the hub insert is rotatable and the other of the hub member or the hub insert is stationary.

In another aspect, a rotary filling machine includes a hub member including a first end a second end and an internal bore extending from the first end toward the second end, the internal bore defining an inner surface portion with a plurality of material transfer openings. A hub insert has a first end and a second end, at least part of the hub insert disposed within the bore, wherein the part of the hub insert includes an external sidewall defining an outer surface portion that includes a plurality of material transfer openings. One of the hub member or the hub insert is rotatable and the other of the hub member or the hub insert is stationary. The inner surface portion and the outer surface portion are in an axially aligned and mating relationship such that rotation of the one of the hub member or the hub insert causes a relative sequential movement in and out of fluid transfer alignment as between each of the material transfer openings of the hub member and each of the material transfer openings of the hub insert.

In a typical machine of the foregoing type, a plurality of filling nozzles, wherein each material transfer opening of the one of the hub member or the hub insert feeds material to a respective one of the filling nozzles, wherein the filling nozzles rotate with the one of the hub member or hub insert.

DETAILED DESCRIPTION

One embodiment of a rotary filling machine310is shown inFIGS. 1 and 2and includes a product tank312that holds liquid or other flowable material and a pump314for feeding the flowable material to the filling assembly316along flow path317. The filling assembly includes a hub member318and hub insert326, details of which are shown inFIGS. 3A-3C and 4-5. The hub member includes an upper end320a lower end322and an internal bore324extending from the upper end toward the lower end. The hub insert326has an upper end328and lower end330, and at least part of the hub insert (e.g., here the lower part) is disposed within the bore324. The hub member318is rotatable (e.g., via a shaft332and coupling334) and the hub insert326is stationary. As the hub member318rotates, flowable material is pumped to an inlet336of the hub insert326and is sequentially delivered to feed outlets338of the hub member, which in turn are connected by flow paths339to provide flow to respective filling nozzles340, which also rotate with the hub member318, as does filling nozzle stabilizing plate341. The filling nozzles340have lower outlet openings to deliver the flowable material into respective containers (not shown). Typically, the containers also rotate synchronously with the hub member318during filling by way of a container transport system. In some cases, the container transport system includes container supports/holders that raise and lower the containers relative to the lower output ends of the nozzles340during filling operations to achieve a bottom up fill of the containers. In other cases, the lower ends of the filling nozzles340may simply be positioned at the top opening of the containers for filling, in which case the containers need not be raised and lowered during actual filling.

FIGS. 3A-3C and 4-5show a detailed embodiment of the hub member318and hub insert326. The hub insert326includes one material inlet336and the hub member318includes six feed outlets338. Here, the material inlet336and the feed outlets are defined in part by bevel seat threaded fittings. It is recognized that the number and size of the inlets and outlets could vary.

The internal bore324of the hub member defines an inner surface portion360with multiple (here six) material transfer openings362, one for each feed outlet338. The hub insert326includes an external sidewall364defining an outer surface portion366that includes multiple (here two) material transfer openings368. The material inlet336feeds both of the transfer openings368via a vertically extending main flow passage379that connects with two lateral flow passages380, where each lateral flow passage runs to a respective one of the transfer openings368. Notably, the transfer openings368widen circumferentially to form transfer pockets that have an entry edge367and exit edge369that is substantially vertically oriented, where each opening/pocket368is identical in shape and size to the other. Each of the material transfer openings362is of identical shape and size to the other material transfer openings362.

The inner surface portion360and the outer surface portion366are in an axially aligned (e.g., along a vertical axis370) and mating (e.g., with surface portions360and366in close proximity) relationship such that rotation of the hub member326causes a relative sequential movement in and out of fluid transfer alignment as between each of the hub member material transfer openings368and each of the hub insert material transfer openings362. Here, both surface portions360and366are configured to define right circular cylinders, which run parallel to the rotational axis370, but variations are possible.

The bore324defines an annular shoulder372and the upper portion of the hub insert326includes an enlarged diameter to define a downwardly facing annular surface374that sits on the shoulder372. This arrangement helps to define the proper axial position of the hub insert relative to the hub member. An upper bearing channel376and a lower bearing channel378may be provided for ease of relative rotation of the hub member relative to the hub insert.

As seen inFIG. 5, a circumferential extent φ1of each of the openings368is defined by entry and exit edges367and369of the opening, and the circumferential extent φ1is larger than the circumferential angular extent of each of the openings362. The six openings362are circumferentially spaced uniformly so that the angle between the circumferential center of one opening362to the next is defined by (360°)/(# of openings362), which here is 360°/6 or sixty degrees. The circumferential angular extent φ1is set to match the center-to-center circumferential angular spacing of the openings362, and a slight angular offset between the openings368is provided (e.g., five degrees or less, such as on the order of about one to three degrees). As a result, the circumferential length or angular extent φ2of outer surface portion366that includes the openings368. which extent defines the angular fill zone or circumferential fill zone range of the assembly, is slightly greater than the sum of the circumferential extents φ1of the openings368.

One or more upper annular seal members382and one or more lower annular seal members384are located between the inner surface portion360and the outer surface portion366at respective locations above and below the zone of vertical alignment between the hub member material transfer openings362and the hub insert material transfer openings368. In one embodiment, the seal members382and384may be formed as spring seals that sit at least partially within circumscribing recesses of the wall of the axial bore324. However, other types of annular seals could be used, and the circumscribing recesses could be formed on the outer surface of the hub insert wall.

In operation, as the hub318rotates, each hub member material transfer opening362moves sequentially past both hub insert material transfer openings368for the purpose of filling a container. Notably, based upon the common shape and size of the transfer openings368, the common shape and size of the transfer openings362and the sizing of the circumferential extent φ1of each transfer opening368to match the circumferential spacing between the transfer openings362, a uniformity and consistency of material flow in the system is achieved. In particular, based upon the dimensions, spacing and shapes of the respective transfer openings362and368, each transfer opening/pocket368is at all times aligned with the same total flow area of transfer opening(s)362, whether that total flow area is made up of a single transfer opening362or parts of two transfer openings362. This feature can be seen well inFIG. 5, where a counterclockwise rotation of the hub member318is assumed for the following discussion. Here, the material transfer opening368-1on the left side of the cross-section is aligned with both a leading part of material transfer opening362-1and a trailing part of material transfer opening362-2, with the total flow area of the parts of the material transfer openings362-1and362-2aligned with pocket368-1matching the total flow area of a single transfer opening362. Likewise, the material transfer opening368-2on the right side of the cross-section is aligned with a leading part of material transfer opening362-2and a trailing part of material transfer opening362-3, where the total flow area of the parts of the material transfer openings362-2and362-3that are aligned with the pocket368-2matches the total flow area of a single transfer opening362. Thus, the material transfer openings368and the material transfer openings362are collectively sized, positioned and shaped so that the size of the flow area of the transfer openings362that is aligned with each transfer opening368is always substantially the same. That is, a hub member material transfer opening flow area that is aligned with each material transfer opening of the hub insert is always substantially the same and, here, is always substantially equal to a flow area defined by an inlet configuration of a single material transfer opening362of the hub member. In the subject configuration, each stator pocket never sees two full rotor openings at the same time.

In the above embodiment of the rotary filling machine, the filling nozzles340do not include any flow control independent of operation of the pump314and alignment or non-alignment of each material transfer opening362with the material transfer openings368. This arrangement is most often used for more viscous flowable materials. However, in other embodiments the filling nozzles could be formed at the lower ends of filling heads that provide the ability for independent control of the open or closed state of the filling nozzle outlet opening, which is useful for less viscous materials.

In this regard, reference is now made toFIGS. 6-10showing another embodiment of a rotary filling machine10that includes a product tank12that holds liquid or other flowable material and a pump14for feeding the flowable material to the filling assembly16. The filling arrangement includes a hub member18including an upper end20a lower end22and an internal bore24extending from the upper end toward the lower end. A hub insert26has an upper end28and lower end30, and at least part of the hub insert (e.g., here the lower part) is disposed within the bore24. The hub member is rotatable (e.g., via a shaft32and coupling34) and the hub insert is stationary. As the hub member18rotates, flowable material is pumped to one or more inlets36of the hub insert26and is delivered to feed outlets38of the hub member, which in turn are connected to provide flow to filling heads40, which also rotate with the hub member18. The filling heads deliver the flowable material into respective containers42(e.g., here bottles) by nozzle portions48. The containers42also rotate synchronously with the hub member18during filling by way of a container transport system44that may include container supports/holders46that raise and lower the containers42relative to the lower output ends of the nozzles48during filling operations to achieve a bottom up fill of the containers42. Here, container42-1shows a container at an initial stage of fill on a raised support46and container42-2shows a container after filling is completed and the container42-2has been lowered and transferred to a take-away conveyance mechanism50. The nozzles48may include internal closing mechanisms52that are moved to seal the nozzle opening once filling is completed in order to avoid drips.

FIGS. 7-10show a detailed embodiment of the hub member18and hub insert26. The hub insert26includes two material inlets36and the hub member18includes six feed outlets38. Here, both the material inlets and the feed outlets are defined in part by bevel seat threaded fittings (e.g., in the case of inlets36, two 3 inch diameter fittings, and in the case of outlets38, six 2 inch diameter fittings). However, it is recognized that the number and size of the inlets and outlets could vary.

The internal bore24of the hub member defines an inner surface portion60with multiple (here six) material transfer openings62, one for each feed outlet38. The hub insert26includes an external sidewall64defining an outer surface portion66that includes multiple (here two) material transfer openings68. Here, each material inlet36feeds a respective one of the transfer openings68via respective flow passages80. However, it is recognized that variations are possible, such as a single inlet36connected to an initial passage that splits to form both flow passages80.

The inner surface portion60and the outer surface portion66are in an axially aligned (e.g., along the vertical axis70) and mating (e.g., with surface portions60and66in close proximity, such as sliding contact) relationship such that rotation of the hub member26causes a relative sequential movement in and out of fluid transfer alignment as between each of the hub member material transfer openings62and each of the hub insert material transfer openings68. Here, both surface portions60and66are configured to define right circular cylinders, but variations are possible. The bore24defines an annular shoulder72and the upper portion of the hub insert26includes an enlarged diameter to define a downwardly facing annular surface74that sits on the shoulder72. This arrangement helps to define the proper axial position of the hub insert relative to the hub member. Upper and lower bearing arrangements76and78may be provided for ease of relative rotation of the hub member relative to the hub insert.

The circumferential extents φ1of each of the opening68and overall circumferential extent φ2are the same as described above with respect toFIG. 5. One or more upper annular seal members82and one or more lower annular seal members84are also provided.

The hub insert26is also provided with a through passage90from top to bottom that facilitates feeding electrical wiring92through the insert. Electrical wiring92may be for the purpose of controlling variable flow valves (not shown) along each of the flow passages80so that the flow of material can be controlled as desired. The wiring may also be used to control the filling heads. Moreover, the hub insert may include an air inlet port94that feeds to an annular recess96that is axially aligned with ports98of the hub member for the purpose of controlling the opening and closing the filling heads via air pressure.

In the case of both of the above embodiments, a controller100(FIGS. 2 and 6) may be provided for assuring synchronous and appropriate operation of the various components of the filling machine. In this regard, as used herein, the term controller is intended to broadly encompass any circuit (e.g., solid state, application specific integrated circuit (ASIC), an electronic circuit, a combinational logic circuit, a field programmable gate array (FPGA)), processor(s) (e.g., shared, dedicated, or group—including hardware or software that executes code), software, firmware and/or other components, or a combination of some or all of the above, that carries out the control functions of the filling machine or the control functions of any component thereof.

The subject rotary filling system, utilizing a hub member with a hub insert, provides advantages over the prior art plate type arrangements. In particular, less maintenance is required, sealing is improved, and cleanability is enhanced (including the ability to clean in place without disassembly).

It is to be clearly understood that the above description is intended by way of illustration and example only, is not intended to be taken by way of limitation, and that other changes and modifications are possible.

For example, while the above embodiments include inner surface portions60,360and outer surface portion66,366of right circular cylinder configuration, other surface portion configurations are possible, provided such surface portions readily mate while at the same time permitting relative rotation. In this regard,FIG. 11shows an embodiment in which the inner mating surface portion160of the hub member118and the outer mating surface portion166of the hub insert126are both tapered to provide frustoconical configurations, which preferably have an angle of inclination al that is offset from the vertical center and rotational axis170by no more than 25°, such as no more than 20°, such as no more than 15°). A single top inlet136feeds material along a main passage180that splits to two passages180-1and180-2for feeding two material transfer openings (not shown) of the hub insert126. Annular seal members182and184are also shown.

As another example, while the embodiments above contemplate the hub member as the rotatable part of the assembly, the reverse could be true. In this regard, reference is made toFIGS. 12 and 13showing an assembly in which the hub member218is stationary and the hub insert226is rotated (e.g., via shaft232). Here, the hub member includes two material inlet openings236that feed flowable material to two respective material transfer openings268and the hub insert226includes six material transfer openings262that move in and out of rotational alignment with openings268during hub insert rotation. Each material transfer opening262feeds material to a respective one of the feed outlets238at the bottom of the hub insert, with each feed outlet238connected to tubing/piping225that feed respective filling heads (not shown). Annular seal members282and284are also shown.

In other embodiments the hub insert could be moved in and out of the hub member through the bottom end of the hub member, and in such cases an annular shoulder on the hub insert could provide a bearing surface for part of the hub member.

In each of such embodiments and implementations, the rotary filling machine takes a bulk of a flowable product and automatically divides it into equal parts merely by rotation; passing it through the hub member and hub insert, operating as a volumetric filler. The rotary hub/insert turret is driven in lock-step with the positive displacement filler pump for accurate filling tolerances (i.e., hub rotation speed synced to pump speed, such as by the machine controller with servo-motors driving bot the hub and the pump). The length of each of the material transfer openings in the stationary part of the hub member/hub insert combination should be exactly the same as the center-to-center spacing between the material transfer openings of the rotating part of the hub member/hub insert combination. For example, in the case of a rotating hub member with 6 transfer openings and corresponding outlet ports, the spacing is 360°/6=60°. In such case, all material transfer openings in the stationary hub insert should be exactly 60° in circumferential length with about a 1° separating web between adjacent transfer openings, creating a 121° circumferential fill zone range for an assembly in which the stationary hub insert includes two transfer openings. One long transfer opening in the stationary hub insert cannot transfer (divide) evenly if it sees multiple rotating hub openings for any extended period of time, so two full transfer openings of the rotor hub member should not be in a stator hub insert transfer opening at the same time, as such will causes erratic container fills.

As noted above the number of transfer openings can vary. For example, in the case of a rotating hub member with twelve transfer openings and corresponding outlet ports, the spacing is 360°/12=30°. If the stationary hub insert includes six transfer openings, the length of each transfer opening will be 30°, with five 1° webs between the openings, for a total circumferential fill zone range of 185° for the assembly. Such an embodiment results in long duration filling which equates to high capacity for only 12 filling stations.

Other variations and modifications are also possible.