Abstract:
A machine consisting of a vertically mobile liquid manifold filling system, and a horizontally mobile carriage for maneuvering pallets under a multi-head filler, for simultaneously filling entire pallet tiers of empty containers, such as 2.5 gallon metal or plastic jugs, bottles, or pails, 5.0 gallon metal or plastic jugs, bottles or pails, or 30-55 gallon metal or plastic drums, requires only the labor to lift and place empty containers onto a pallet, instead of the conventional physical handling and palletizing, of heavy, prefilled containers.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates to a labor saving, high speed, high volume liquid filling machine for larger containers that are to be palletized for shipment. Typically, most pallets of product are loaded to about 2,000-3,000 pounds, more or less, as would readily be handled by a forklift pallet moving and handling device. Typically, most shipping pallets are designed to be loaded two abreast in a commercial shipping vehicle, be it a truck, or a sea shipping container, with the maximum container or truck weight topping out at around 40,000 pounds, more or less. Assuming then, a liquid product with a specific gravity of 1.2, or 10 pounds per gallon, a pallet could contain 40-60 five gallon containers, each weighing 50 pounds, or 80 to 120 two and one half gallon containers, each weighing 25 pounds, or four 55 gallon drums, per pallet weighing 2,200 pounds, each assumption, having to handle, typically with labor, previously fill containers, represents a formidable, costly and laborious handling task.  
           [0002]    Liquid filling machines are already known that efficiently fill containers, filled and weighted to then be handled in a separate process of palletization, but this invention combines both processes, improving on both aspects, by mass filling 16-25 containers, on a pallet tier simultaneously, which have been placed there on their empty weight, in less time than it typically takes to fill that same amount of containers, by conventional means, and by eliminating any further handling of these filled containers.  
         SUMMARY OF THE INVENTION  
         [0003]    The present invention provides that a smaller labor force be required to package and ready for shipment, palletized liquid containers, at a lower cost. This is accomplished with the present invention by the described machine that maneuvers a pallet of empty light weight containers, tier by tier, in and out of the machine, filling all of them simultaneously and accurately, with a prescribed amount of fluid, until the desired number of tiers, and/or weight is achieved, all in a labor saving process. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0004]    The FIGURE shows a preferred embodiment of the liquid filling apparatus of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0005]    A fast, labor saving, high volume, liquid filling apparatus will now be described according to a preferred embodiment of the invention in conjunction with the FIGURE.  
         [0006]    In the present invention, vertical and horizontal movements are integrated to achieve an efficient liquid filling apparatus.  
         [0007]    A multidimensional, integrated frame  10 , comprising a vertical and a horizontal phase is provided. A vertical elevator shaft and a horizontal track system is housed in the frame.  
         [0008]    A reciprocating pallet transport system is provided for moving pallets of containers to be filled and capped, in and out, from under the elevator shaft. It includes a motorized and controlled wheeled carriage  20 , riding on tracks, capable of holding two or more pallets  150 .  
         [0009]    As illustrated in the FIGURE, the wheeled carriage  20  rides on carriage wheels  30 , and automatically controlled as described in greater detail later.  
         [0010]    A motorized and controllable vertical elevator  190  is provided within the elevator shaft of the frame  10 . A pressurized boom and a multi-head nozzle apparatus  80 , mounted on the elevator  190 , is provided for filling individual containers  130  that are placed empty on the pallet  150 . The pressurized boom and multi-head nozzle apparatus  80  includes metering valves  220 , adjustable spouts  200  and a manifold  210  for plumbing.  
         [0011]    A pumping system is provided. Although the fluid source is not shown in the FIGURE, it supplies liquid to a fluid pump  60 , through a flexible fluid feed hose  50 , and through a fluid control valve  70 . Thus, a bulk solution from a holding tank is accurately and precisely pumped and dispensed into the containers on the pallet  150 , as indicated by the partially filled containers  110 .  
         [0012]    Overhead mounting brackets for air operated container cap closure devices are also provided (not shown). After the containers  110  are filled with a predetermined quantity of the bulk liquid, they are capped accordingly, by an automated, motorized multi-pail lid fastening device.  
         [0013]    Electrical and automation control panels are provided for the carriage  20 , the elevator  190 , the pump  60 , the manifold  210  and the air operated closure devices. Thus, the present invention provides a fast, labor saving, high volume, liquid filling apparatus.  
         [0014]    The movement of the carriage  20  is automated by use of a hydraulic pump  170  which controls a hydraulic carriage motor  180  in the wheel  30 . A carriage control sensor  100  is connected to the hydraulic pump  170 , for sending control signals to the hydraulic pump  170  so that the movement of the carriage frame  20  is accurately controlled.  
         [0015]    In addition, the movement of the elevator  190  is automated by an elevator motor  40  via a cable. A microprocessor  160  sends a control signal to the elevator motor  40  to control movements of the elevator  190  to coordinate with the dispensing of liquid in the containers. An elevator control sensor  90  is provided for sensing vertical position of the elevator  190  and facilitates the automation of the elevator motor  40 .  
         [0016]    According to the present invention, a high output metering system is provided with the fluid pump which feeds the nozzle filling apparatus  200  for each container  110  and is controlled on a time basis, through plumbing and the manifold  210  designed for low friction loss, for the uniform and precise feeding of individual drops, for each individual container  100 , on the tier of the pallet  150  being filled, and in a precise manner checked with pump starting and stopping, coupled with air operated start/stop valves, through specifically and similarly sized and pressurized metering orifice plates.  
         [0017]    In other embodiments of the invention, the high output metering system is controlled on a weight basis, a metered basis, or a gravity fill basis.  
         [0018]    As illustrated, the reciprocating movement of the carriage frames  20  allows one pallet  150  to be undergoing a filling procedure while another pallet  150  which holds filled containers  120 , receives a second tier of empty containers  130  on top. Thus, new tiers of empty containers are placed on top of the tiers having filled containers, so that the reciprocating movement of the carriage frame  20  provides a constant supply of empty containers under the pressurized boom and multi-head nozzle apparatus  80 .  
         [0019]    As each tier is received in the frame  10 , the elevator  190  housing the liquid filling assembly precisely raises and stops the liquid filling assembly above the next tier of empty containers, while simultaneously and precisely inserting a filling tube into each container.  
         [0020]    Since the carriage system transports at least two pallets of containers back and forth under the elevated liquid filling system, while one pallet of empty containers is being filled, the other pallet is moved out from under the filler and exposed so that caps or lids can be placed on the recently filled containers, and a new or subsequent tier of empty containers  130  placed on top of the completed containers  120 , is ready to be transported, back under the filler. The process repeats until a completed pallet with a desired number of tiers of containers is filled, capped and readied for shipment.  
         [0021]    In the nozzle filling system of the present invention, when the pressure through a high pressure metering orifice for each container is reduced by exiting through a larger diameter of looped tubing, entry pressure into the container being filled is reduced, thus, eliminating foaming of the product for rapid filling.  
         [0022]    Thus, in the present invention, an entire pallet of containers can be filled and as it is automatically moved away from the dispensing system, another pallet of containers can be moved under the dispensing system and filled. With this movement, one pallet can be receiving caps or another tier of empty containers while another pallet is being filled, thus, providing for an efficient operation.  
         [0023]    Moreover, this apparatus reduces the amount of labor required by an operator because the pallets of containers are moved under the dispenser by an automated device, and the associated vertical elevation of the dispenser is automated so as to facilitate the filling of subsequent tiers of pallets of containers with reduced physical labor by the operator.  
         [0024]    While only certain embodiments of the invention have been specifically described herein, it will be apparent that numerous modifications may be made without departing from the concept and scope of the invention.