Patent Publication Number: US-7584770-B2

Title: Integrated product filler

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   The present application claims priority to U.S. Provisional Patent Application Ser. No. 60/763,216 filed Jan. 30, 2006, the disclosure of which is incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   The present invention relates generally to automated dispensing devices and, more particularly, to an apparatus for dispensing viscous products in production settings. 
   Automated fillers for dispensing viscous food product in production settings have evolved to a state wherein several devices connected in series provide the requisite functions of storage and measured dispensation of the viscous food product. In meeting these functions, conventional automated fillers often employ a viscous food product storage, a device for withdrawal of the viscous food product from the viscous food product storage, a mechanism for transferring the viscous food product from the storage device for withdrawal of the viscous food product from the viscous food product storage to a dispensing apparatus, a dispensing valve and a tube attached at one end to the dispensing valve and a second end positioned at a point of discharge. 
   While such conventional fillers provide for the automated dispensing of viscous food product, improvements may be realized over current designs and arrangements. For instance, given the number of discreet components or parts currently employed to accomplish the filling process, trouble shooting, adjustment and timing of the various components may be difficult and time consuming. Additionally, because the actuators of conventional fillers are often of analog design, the range and operating parameters of the fillers are typically limited. 
   BRIEF DESCRIPTION OF THE INVENTION 
   The above-mentioned limitations associated with conventional automated fillers are addressed by embodiments of the present invention and will be understood by reading and studying the following specification. 
   According to one aspect of the present invention, an integrated filler system to transfer a filler product from a filler product source to a product receptacle includes a cylinder housing and a pallet valve disposed within the cylinder housing, the pallet valve including a product flow aperture. The integrated filler system also includes a piston inserted in a valve bore of the pallet valve, a linear actuator connected to the piston to selectively actuate a linear travel of the piston within the valve bore. The integrated filler system further includes a rotary actuator connected to the pallet valve to selectively position the product flow aperture to fluidly communicate with one of a product input port and a product output port formed in the cylinder housing. 
   In accordance with another aspect of the present invention, a servo controlled integrated filler system includes a cylinder housing having a cylinder bore therein, a product input port, and a product output port. The servo controlled integrated filler system also includes a pallet valve disposed within the cylinder bore containing at least one product flow aperture therein and a piston positioned in a valve bore of the pallet valve. The servo controlled integrated filler system further includes a first actuator connected to the piston to actuate a first movement thereof, a second actuator connected to the pallet valve to selectively position the at least one product flow aperture to align with one of the product input port and the product output port, and a servo controller system to control movement of at least one of the first actuator and the second actuator. 
   In accordance with yet another aspect of the present invention, a method for transferring a filler product from a filler product source to a product receptacle includes the step of connecting an integrated filler system to a filler product source, the integrated filler system including a pallet valve disposed within a cylinder bore of a cylinder housing, and wherein the cylinder housing includes a product input port and a product output port selectively fluidly connected to the cylinder bore. The method also includes the steps of aligning a product flow aperture of the pallet valve with the product input port to place a valve bore in the pallet valve in fluid communication with the filler product source and displacing a piston to draw a filler product from the filler product source. The method further includes the steps of aligning the product flow aperture with the product output port; and displacing the piston to discharge the filler product through the product flow aperture and the product output port. 
   Additional advantages and novel features will be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of embodiments of the invention. Additionally, advantages may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a schematic representation of a conventional filler system. 
       FIG. 2  is a schematic representation of a filler system according to one embodiment of the present application. 
       FIG. 3  is a representative perspective view of an integrated filler according to one embodiment of the present application. 
       FIG. 4  is a representative perspective partially exploded view of an integrated filler according to one embodiment of the present application. 
       FIG. 5  is a schematic flow chart representing the steps of a method for transferring a filler product from a source to a receptacle. 
   

   Like reference numbers and designations in the various drawings indicate like elements. 
   DETAILED DESCRIPTION OF THE INVENTION 
   In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific illustrative embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical, and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense. 
     FIG. 1  depicts schematically a conventional filler system  500  that includes viscous food product storage  501  and product cylinder  502  including piston  509  actuated in a reciprocating fashion by actuator  504 . In operation, piston  509  can be displaced by actuator  504 , thereby withdrawing viscous food product FP from the viscous food product storage  501  through conduit  503  and pallet valve  506  into the body of product cylinder  502 . Upon return of piston  509  by actuator  504 , viscous food product FP is forced through conduit  505  into pallet valve  506 . Pallet valve  506  includes valve position actuator  507 . Pallet valve  506  operates as a two position valve, a first position that permits viscous food product FP to pass from conduit  503 , through conduit  505  into product cylinder  502 , and a second position which permits passage of viscous food product FP from product cylinder  502  through conduits  505  and  511  to dispense valve  508 . When dispense cylinder actuator  508  and product cylinder actuator  504  are actuated, viscous food product FP is transferred through pallet valve  506  into dispense conduit  510  to be discharged as product receptacle PR passes under dispense conduit  510  on production line L. As shown, product receptacles PR proceed in a process direction P on production line L. 
   Referring to  FIG. 2 , filler system  10  includes filler product source  11  containing filler product FP. In some embodiments, filler product FP comprises viscous food product, such as, for example, sauce, gravy, liquid, etc. In other embodiments, filler product FP comprises any suitable viscous product dispensed in a production setting. For purposes of illustration in this disclosure, filler system  10  will be described primarily with reference to a food production environment in which filler product FP comprises viscous food product. 
   In the embodiment illustrated in  FIG. 2 , filler product source  11  is connected to integrated filler  20  at product input port  21 . As shown, filler product FP is discharged from integrated filler  20  at nozzle  27 . As product receptacle PR proceeds in process direction P on production line L, stream S of transferring filler product FP is dispensed from integrated filler  20  into product receptacle PR as it passes under nozzle  27  positioned above production line L. Linear actuator servo controller  16  is shown connected to linear actuator  30 . Linear actuator servo controller  16  is adapted to control a stroke speed and a stroke length of linear actuator  30  as discussed herein below. Rotary actuator servo controller  17  is shown connected to rotary actuator  40  and is adapted to control an angular speed and an angular displacement of the rotary actuator  40 , also discussed herein below. Control device  15  is connected to linear actuator servo controller  16  and rotary actuator servo controller  17  and is adapted for the programmable control and adjustment of linear actuator servo controller  16  and rotary actuator servo controller  17 . 
   In a preferred embodiment, programmable control and adjustment of linear actuator servo controller  16  and rotary actuator servo controller  17  may be accomplished in real time, permitting “on the fly” adjustment of filling parameters. In one preferred embodiment, linear actuator servo controller  16  and rotary actuator servo controller  17  comprise pneumatic servo controlled motors, such as, for example, the LS-V series linear servo controlled motors manufactured by Enfield Technologies of Trumbull, Conn., USA. Control device  15  may comprise a system controller, such as, for example, the LS-C Series Pneumatic Device Controller also manufactured by Enfield Technologies of Trumbull, Conn., USA. 
   Referring to  FIG. 3 , one exemplary embodiment of integrated filler  20  is shown including cylinder housing  25  having product input port  21  and nozzle  27 .  FIG. 3  also shows integrated filler  20  including linear actuator  30  and rotary actuator  40 . 
   Referring to  FIG. 4 , one exemplary embodiment of integrated filler  20  is shown in a partially exploded view. Integrated filler  20  is shown including cylinder housing  25  having product input port  21  and nozzle  27 . Cylinder housing  25  is shown in a partial cutaway showing product output port  22 . Both product input port  21  and product output port  22  fluidly communicate with cylinder bore  26  of cylinder housing  25 . As seen, cylinder bore  26  is formed along longitudinal axis A. Nozzle  27  is adapted for interchangeable fit in recess  29  of cylinder housing  25 . In the illustrated embodiment, nozzle  27  includes discharge aperture  28 . 
   Integrated filler  20  also includes linear actuator  30  and rotary actuator  40 , as well as pallet valve  50  including a substantially cylindrical segment  52  adapted for sliding fit within cylinder bore  26 . Linear actuator  30  attaches to cylinder housing  25  employing cylinder mount  34 . Linear actuator  30  includes a selectively extendible and retractable rod  31 , which attaches to piston  35 . Piston  35  is adapted for sliding or reciprocating excursion within valve bore  51  of pallet valve  50 . In the illustrated embodiment, piston  35  includes a pair of seals  32  and  33  for providing a leak-proof sliding fit within valve bore  51  of pallet valve  50 . 
   Cylindrical segment  52  of pallet valve  50  is concentrically aligned with longitudinal axis A of cylinder bore  26 . Cylindrical segment  52  is further adapted for rotational movement within cylinder bore  26  about longitudinal axis A. As shown, sidewall  57  defines cylindrical segment  52  which includes valve bore  51  formed along longitudinal axis A. Pallet valve  50  includes product intake aperture  55  and product discharge aperture  56  formed through sidewall  57  of cylindrical segment  52 . In the illustrated embodiment, product intake aperture  55  is adapted for selective alignment with product input port  21  upon operation of rotary actuator  40 . Similarly, product discharge aperture  56  is adapted for selective alignment with product output port  22  upon operation of rotary actuator  40 . Rotary actuator  40  attaches to pallet valve  50  via drive shaft  41  that extends through a drive port (not shown), which is coextensive to cylinder bore  26 . 
   In a use environment, integrated filler  20  may take on a variety of configurations or embodiments. For instance, integrated filler  20  may be positioned in a housing or attached to peripheral or related devices or equipment. As another example, rotary actuator  40  may be configured as a direct drive or a 90° drive, and may be connected to cylindrical segment  52  employing a variety of drive configurations. Additionally, cylindrical segment  52  may include one or more product flow apertures as preferred by design or application. 
     FIG. 5  is a flow chart illustrating a method  100  for transferring a filler product from a filler product source to a product receptacle. In some embodiments, the method  100  employs an integrated filler system including a cylindrical pallet valve disposed within a cylinder bore of a cylinder housing, the cylinder bore including a product input port and a product output port, both selectively fluidly connected to the cylinder bore. 
   As shown in  FIG. 5 , in a first step  101 , a product flow aperture of a pallet valve is selectively positioned in a first position wherein the product flow aperture is aligned with the product input port of the cylinder housing so that a valve bore of the cylindrical pallet valve fluidly communicates with the filler product source through the product input port. In a next step  102 , a piston is displaced in the valve bore of the cylindrical pallet valve, thereby drawing filler product into the valve bore from the filler product source through the product input port and the product flow aperture. In a step  103 , the product flow aperture is selectively positioned in a second position wherein the product flow aperture is aligned with the product output port of the cylinder housing so that the filler product may be discharged from the valve bore through the product output port. In a final step  104 , the piston is displaced into the valve bore of the cylindrical pallet valve, thereby discharging the filler product from the valve bore through the product flow aperture and the product output port. 
   In use, and referring again to  FIGS. 2 and 4 , rotary actuator  40  initiates operation by selectively positioning cylindrical segment  52 , referring to  FIG. 4 , in a first angular position by rotation along longitudinal axis A until product intake aperture  55  is aligned with product input port  21  of cylinder housing  2  so that valve bore  51  of pallet valve  50  fluidly communicates with filler product source  11 , shown in  FIG. 2 , through product input port  21 . Referring to  FIG. 4 , linear actuator  30  operates to displace piston  35 , thereby retracting piston  35  within valve bore  51  of pallet valve  50 . As piston  35  retracts within valve bore  51 , filler product FP, shown in  FIG. 2 , is drawn into valve bore  51  from filler product source  11 , shown in  FIG. 2 , through product input port  21  and product intake aperture  55 . Referring to  FIG. 4 , once piston  35  has reached a selected linear position within valve bore  51 , rotary actuator  40  again initiates operation by selectively positioning cylindrical segment  52  in a second angular position by rotation along longitudinal axis A until product discharge aperture  56  aligns with product output port  22  of cylinder housing  25 . Linear actuator  30  operates to displace piston  35 , thereby pushing piston  35  into valve bore  51 . As piston  35  extends into valve bore  51 , filler product FP, shown in  FIG. 2 , is discharged from valve bore  51  through product output port  22  and nozzle  27 . 
   The systems and methods described above present a number of distinct advantages over conventional automated fillers for dispensing viscous product. For example, by combining the structure and functionality of the product cylinder and the pallet valve, integrated filler  20  enjoys advantages in speed of operation over conventional systems. Additionally, certain conductive tubing is eliminated in such combination, resulting in increased speed of operation. 
   Advantages of the systems and methods described above may as well be found in the degree of control over operation parameters realized. More particularly, and referring to  FIG. 2 , in some embodiments, linear actuator  30  is controlled by linear actuator servo controller  16  and rotary actuator  40  is controlled by rotary actuator servo controller  17 . Servo control of the actuators advantageously permits the ease and convenience of “on the fly” adjustment of the actuators, i.e., the actuators can be remotely adjusted during operation and the results of said adjustment may be observed in real time. 
   Additionally, the control device  15  permits an operator to program for a variety of flow dispensing characteristics. By way of illustration, the length of the stroke of linear actuator may be programmed for any given filler product in order to vary the amount of filler adder to any particular receptacle. Additionally, the speed of travel of the linear actuator may be varied to control the volume of flow at the nozzle. Similarly, a speed of rotation of cylindrical segment  52  and the angular position of product discharge aperture  56  may be controlled to regulate filler discharge. Additionally, various combinations of speed of linear actuator travel, speed of rotary actuator travel and configuration discharge aperture  28  of nozzle  27  may be employed to provide a wide range of selectable and programmable flow characteristics. 
   Therefore, according to one embodiment of the present invention, an integrated filler system to transfer a filler product from a filler product source to a product receptacle includes a cylinder housing and a pallet valve disposed within the cylinder housing, the pallet valve including a product flow aperture. The integrated filler system also includes a piston inserted in a valve bore of the pallet valve, a linear actuator connected to the piston to selectively actuate a linear travel of the piston within the valve bore. The integrated filler system further includes a rotary actuator connected to the pallet valve to selectively position the product flow aperture to fluidly communicate with one of a product input port and a product output port formed in the cylinder housing. 
   In accordance with another embodiment of the present invention, a servo controlled integrated filler system includes a cylinder housing having a cylinder bore therein, a product input port, and a product output port. The servo controlled integrated filler system also includes a pallet valve disposed within the cylinder bore containing at least one product flow aperture therein and a piston positioned in a valve bore of the pallet valve. The servo controlled integrated filler system further includes a first actuator connected to the piston to actuate a first movement thereof, a second actuator connected to the pallet valve to selectively position the at least one product flow aperture to align with one of the product input port and the product output port, and a servo controller system to control movement of at least one of the first actuator and the second actuator. 
   In accordance with yet another embodiment of the present invention, a method for transferring a filler product from a filler product source to a product receptacle includes the step of connecting an integrated filler system to a filler product source, the integrated filler system including a pallet valve disposed within a cylinder bore of a cylinder housing, and wherein the cylinder housing includes a product input port and a product output port selectively fluidly connected to the cylinder bore. The method also includes the steps of aligning a product flow aperture of the pallet valve with the product input port to place a valve bore in the pallet valve in fluid communication with the filler product source and displacing a piston to draw a filler product from the filler product source. The method further includes the steps of aligning the product flow aperture with the product output port; and displacing the piston to discharge the filler product through the product flow aperture and the product output port. 
   Although this invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of this invention. Accordingly, the scope of the present invention is defined only by reference to the appended claims and equivalents thereof.