Patent Publication Number: US-6983577-B2

Title: Circular motion filling machine for processing parallel rows of containers and method

Description:
This is a continuation-in-part of application Ser. No. 09/418,619 entitled Continuous Circular Motion Case Packing And Depacking Apparatus And Method, filed Oct. 15, 1999, now U.S. Patent No. 6,729,103. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention relates to an apparatus and method for filling containers with a liquid, and more particularly to increasing the speed and control of containers being filled by processing containers arranged in a plurality of parallel rows rather than a single row. 
     Heretofore, filling machines have been provided which fill containers, such as bottles, arranged in a single file row. To achieve high production of a single row of empty containers, the filling machine must process the containers at a very high speed. A typical filling machine conveys these bottles in single file and uses a worm feed to separate these bottles because the stationary filling valves are spaced more than the single file bottles. The worm feed increases the space between the bottles and feeds them to a large infeed star wheel. The star wheel, usually 4 feet in diameter, receives the bottles in individual pockets and conveys them underneath the filling valves of a radial filler machine. The radial filler machine is typically 12 to 15 feet in diameter, and includes a filler tube having a plug that inserts into a snap-on fitting that holds the bottle. Typically, the bottle is lifted up to the filler valve when the bottle is being filled. The bottle is then lowered down onto a discharge star wheel. The discharge star wheel usually is 4 feet in diameter, so the entire machine may range from about 16 to 24 feet in overall operating diameter, depending on its configuration and floor plan. Considerable floor space is required for the typical filling machine. Particularly, when considering the bottles or other containers, also have to be capped after the filling operation so that capping stations are also required in the processing space. The basic configuration of a rotary filling machine with feed and discharge wheels is illustrated schematically in FIG. 1 of U.S. Pat. No. 6,026,867. U.S. Pat. Nos. 5,865,225 and 4,053,003 show various prior rotary filling machines, the latter having feed and discharge wheels which transfer containers by two, in radial alignment. 
     The typical radial filler machine processes of line of empty containers. Usually the upper speed limit of the machine is about 1200 containers per minute, or for a typical beverage bottle, about 300 feet per minute. However, at this upper limit of speed, control of the containers and filling process is sometimes unpredictable and hazardous. 
     Accordingly, an object of the invention is to provide a continuous motion filling machine and method having increased production yet may operate at reduced speeds under better control. 
     Another object is to provide an apparatus and method for processing articles in parallel rows having a simple construction with fewer parts providing high reliability. 
     Another object of the present invention is providing continuous circular motion filling machine and method for processing containers arranged in a plurality of parallel rows rather than a single file row, for increasing production. 
     Another object of the present invention is to provide a circular motion filling apparatus and method for processing containers in parallel rows wherein the apparatus may be arranged in different machine and floor configurations, depending on the application being made, with less floor space. 
     Still another object of the present invention is to provide an apparatus and method for filling containers in parallel and serial order where the containers are not lifted during the filling operation and may be processed on a single continuous conveyor. 
     SUMMARY OF THE INVENTION 
     The above objectives are accomplished according to the present invention by providing a continuous circular motion apparatus for filling a group of empty containers conveyed in parallel rows comprising a rotating turret which continuously rotates about a single vertical turret axis, and a plurality of articulating and reciprocating filling heads circularly arranged. The filling heads rotate along a radial path for continuously and successively filling the groups of the containers while being conveyed during a fill operation. A group of filling valves is carried by the filling heads corresponding to the arrangement of the group of containers for aligning with the containers as the filling heads are lowered into engagement with the containers. A filling-head motion converter is operatively connected to the filling heads causing the filling heads to move generally in a straight line motion along a chordal path while the filling heads rotate about the single turret axis and are lowered to engage the containers. A conveyor includes an arcuate section having an arc with a curvature generally corresponding to the radial path, and the filling operation occurs at least in part along the arcuate section. 
     Advantageously, there is an engagement station where the filling heads are lowered to engage empty containers on the conveyor; a release station where the filling heads are raised to disengage from filled containers on the conveyor; and the filling heads have a fill position between the engagement and release stations whereby the containers are filled during a fill operation. A reservoir is carried atop the rotating turret, rotating with the turret, for containing a liquid to be dispensed into the containers. The filling heads include accumulator tanks in fluid communication with the reservoir for receiving liquid to be dispensed into the containers. The group of filling valves carried by the filling head are in fluid communication with the accumulator tank and have an open position for dispensing fluid into the containers and a closed position for blocking the dispensing of liquid after the containers are filled. A vertical motion mechanism is operatively associated with the filling heads for controlling operative vertical positions of the filling heads to engage the containers on the conveyor at an engagement station, and to disengage the containers on the conveyor at a release station as said turret and the filling heads continuously rotate about the single turret axis. 
     The conveyor includes an infeed section and an outfeed section wherein the arcuate section is disposed between the infeed and outfeed sections. The infeed conveyor section includes a generally straight conveyor run for feeding empty containers to the filling heads for engagement. A plurality of capping stations is disposed downstream for placing a cap on filled containers created by filling the empty containers and the outfeed conveyor section includes a generally straight conveyor run for conveying filled containers to the capping stations. The outfeed conveyor section includes a lane assembly for arranging the group of articles in parallel rows for delivery to selective ones of the capping stations for capping the filled containers. 
     According to the invention, a method of filling containers with a liquid during a filling operation includes providing a plurality of circularly-arranged, reciprocating filling heads and continuously rotating the filling heads about a single vertical axis which feeding containers arranged in parallel rows to an engagement station along a conveyor. The filling heads are lowered to sequentially engage the containers along the engagement station, and the filling heads are controlled to move along a straight line path while rotating about the single axis as the filling heads engage the containers. The method includes filling the containers as the containers are conveyed along an arcuate path about the single axis while the filling heads are rotating about the single axis; and raising the filling heads to disengage from said containers after the containers are filled. An infeed conveyor section and the outfeed conveyor sections are arranged parallel to one another, and the method includes arranging a plurality of capping stations along the outfeed conveyor sections for receiving and capping the filled container. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       A construction designed to carry out the invention will now be described, together with other features thereof. 
       The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein: 
         FIG. 1  is a perspective view of a continuous circular motion apparatus and method for filling containers arranged in groups of parallel rows constructed according to the invention; 
         FIG. 2  is a top plan view of the circular motion apparatus and method of  FIG. 1  wherein empty containers are conveyed on a conveyor to an engagement station for engagement with filling heads, a fill operation takes place over an arcuate section of the conveyor, and the filled containers are conveyed by the conveyor to a capping station; 
         FIG. 3  is a top plan view of a continuous circular motion filling apparatus and method of claim  1  having a conveyor which conveys empty containers to an engagement station wherein the fill operation takes places over a greater arc of the conveyor than the fill operation of  FIG. 1  whereupon the filled containers are conveyed to a capping station; 
         FIG. 4  is a simplified side elevation illustrating a continuous circular motion apparatus and method for filling empty containers wherein a turret is illustrated which rotates about a single vertical axis with filling heads circularly arranged about the turret rotating about the single vertical axis; 
         FIG. 5  is a perspective view illustrating empty containers arranged in a group of side-by-side rows being engaged by filler tubes carried by the filling heads arranged corresponding to the group of empty containers; 
         FIG. 6  is a side elevation illustrating a filler tube in section prior to the filling head being lowered into engagement with the container; 
         FIG. 7  is a side elevation with a filler tube in section illustrating a valve of a filler tube engaging an empty container for filling; 
         FIG. 8  is a perspective view illustrating parts of a vertical motion mechanism for controlling the vertical position of the filling heads as they with turret during the filling operation according to the invention; 
         FIG. 9  is a top plan view illustrating a first radial path of a turret and a second radial path of the filling heads according to the continuous circular motion filling apparatus and method of the invention wherein the filling heads are controlled to move along a chordal path of the second radial path as the filling tubes engage the containers in a group; and 
         FIG. 10  is a perspective view with parts omitted illustrating an articulation assembly for converting the circular motion of the filling heads about a radial path into a straight line motion over a predetermined distance so that the filler tubes reliably engage the empty containers. 
     
    
    
     DESCRIPTION OF A PREFERRED EMBODIMENTS 
     Referring now to the drawings, the invention will now be described in more detail. 
     As can best be seen in  FIG. 1 , apparatus and method for filling containers, designated generally as A, is illustrated which is of simple construction and based on a continuous circular motion. The apparatus includes a rotating turret B illustrated in the form of a cage rotating about a single vertical turret axis Y, and a stationary central column  10 . Turret B includes a plurality of circularly arranged support arms  12  which are connected to and generally form a cage rotating about central column  10 , as can best be seen in FIG.  4 . Support arms  12  are carried between upper and lower circular plates  20 ,  22  (FIGS.  2  and  4 ). A plurality of reciprocating processing or filling heads, designated generally as C, are slidably carried on support arms  12  for carrying out a process on articles or containers. In the illustrated embodiment, a particularly advantageous embodiment is disclosed for filling empty beverage containers and the like. When used in the filling process illustrated herein, a reservoir  24  is carried by upper rotating plate  20  and contains a liquid used to fill empty containers  26 . 
     As can best be seen in  FIG. 2 , an article feeder, designated generally, as D, is illustrated for conveying empty containers to an engagement station  28  where the empty containers are operationally engaged by the filling heads over an arc  28   a . Article feeder D includes an infeed conveyor section  30  having a straight run on which containers  26  are conveyed in a group  32  of parallel, linear single-file rows  26   a ,  26   b ,  26   c  and  26   d  to engagement station  28 . For this purpose, a slug feeder, designated generally as  27  (FIG.  1 ), may be utilized to arrange scrambled containers into groups  32  of containers arranged in rows  26   a - 26   d . A suitable slug feeder is disclosed in applicant&#39;s copending application Ser. No. 09/418,619 entitled  Continuous Circular Motion Case Packing and Depacking Apparatus And Method , filed Oct. 15, 1999, which application disclosure is incorporated into the present application by reference. The slug feeder includes a metering section receiving a continuous flow of containers wherein the metering section separates the containers into a plurality of group  32  containers and delivers groups of containers to engagement station  28 . Conveyor  30  includes an infeed section  30   a , an arcuate section  30   b , and an outfeed section  30   c  (FIG.  2 ). Alternately, conveyor  30  may include an arcuate section  30   b  that extends approximately 270 degrees, as shown in FIG.  3 . The embodiment of  FIG. 3  provides a longer arcuate path over which the fill operation may be conducted. Other conveyors and machine configurations may also be had according to the application being made. 
     Referring now in more detail to turret B, as can best be seen in  FIGS. 1 ,  2 , and  4 , turret B includes top plate  20  and bottom plate  22  between which transfer arms  12  are circularly arranged and fixed. Transfer arms  12  are illustrated in the form of steel beams and define the outer limits of a turret cage  34 . Transfer arms  12  rotate in a first radial path R 1  while the filling heads C rotate in a second radial path R 2  (FIG.  9 ). In the illustrated embodiment, there are 10 support arms spaced around the turret cage and 5 filling heads carried by the support arms. The number of support arms and/or filing heads, of course, may vary depending upon the application. A drive for the rotating turret is provided by a ring bearing  36  having an outside ring gear  36   a  affixed to bottom plate  22 , and an inner bearing gear  36   b  affixed to a frame  38  supported on the floor (FIG.  4 ). Gear  36   b  is meshed in driving arranged with ring gear  36   a  and a drive gear  40   a  of a gear motor  40 , also mounted to frame  38 . Within the interior of turret B, as defined by turret cage  34 , is stationary central support or column  10  supported by frame  38 . Affixed to central support column  10  is a cam support drum  42  having a plurality of vertical braces  44  affixed to the central support column by intermediate connector plates  46 . Central support  10  extends through clearance holes (not shown) formed in upper and lower plates  20 ,  22 . In this manner, turret B, as mainly including plates  20 ,  22 , cam support drum  42 , circumferential cam  48 , and support arms is  12 , rotates about stationary support  10 . Circumferential cam  48  surrounds a cam support drum  42  and is affixed to the drum. Cam  48  controls the vertical position of filling heads C as turret B rotates. Cam  48  forms part of a vertical motion mechanism, designated generally as E, described below. The vertical drum braces, circular plates, cams and central support may be affixed together in any suitable manner, such as welding, bolts, and the like to define an integral structure which is stationary. 
     Vertical motion mechanism E controls the vertical position of filling heads C, as can best be seen in  FIGS. 4 and 8 , and includes cam  48  and cam rollers  50  carried by filling heads C. Cam rollers  50  ride on cam  48  and are rotatably carried by guide bearing assemblies, designated generally as  52 , which slide on support arms  12 . Each guide bearing assembly includes a bearing block  52   a  which slides on arm  12 , a pair of support arms  54 . A support tray  56  is carried by support arms  54 , and filling head C is carried by support tray  56 . As cam roller  50  rides up and down on cam  48 , support tray  56  raises and lowers accordingly. In this manner, the vertical position of filling heads C is controlled while rotating with turret B by the track of circumferential cam  48  stationarily affixed to cam drum  42  affixed to stationary central column  10 . It will be noted that liquid reservoir  24  also rotates with turret B and filling heads C so that a flexible fluid connection  60  between reservoir  24  and respective filling head C can be had. The reservoir may be provided with a fluid rotary coupling (not shown) by which the reservoir is replenished from an outside source. 
     As can best be seen in  FIG. 9 , filling heads C move in second radial path R 2  as they are rotated by turret B while support arms  12 , on which they are carried, rotate in first radial path R 1 . In accordance with a particular advantageous aspect of the invention, the circular path of filling heads C is altered over a prescribed distance at engagement station  28 , corresponding to arc  28   a , so that filling heads C move in a straight line path  64 , from a point  64   a  to a point  64   b , and remain aligned with containers  26  during lowering and engagement. In the illustrated embodiment, the straight-line path corresponds to a chordal path of a circle defined by radial path R 2 . In this manner, reliable alignment of the filling heads with a group of articles beneath the filling heads is had at engagement station  28  for operational engagement. For this purpose, a filling-head motion converter assembly, designated generally as F, is provided for causing filling heads C to convert from a circular path to straight line path  64  over a prescribed arc  28   a  of rotation of turret B, depending on the application being made. In the illustrated embodiment the motion converter assembly is provided by an articulated structure that allows relative motion between the turret arms  20  and the filling heads C, as will be more fully described below. 
     Filling heads C will now be described in more detail. As can best be seen in  FIGS. 4 through 8 , each filling head includes an accumulator  70  in the form of a rectangular container which receives liquid from main reservoir  24  to be dispensed in empty containers  26 . Filling heads C include a plurality of filler tubes  72  which are arranged in an array corresponding to the array of  15  containers in group  32 . Each filler tube includes a reciprocating filling element or valve  74  which is spring biased to a closed position (FIG.  6 ). Filling valve  74  includes an outlet end  74   a  and an inlet end having a plurality of end openings  74   b . When filling head C is lowered, outlet end  74   a  of the filling valve engages container opening  26   a  of container  26 . Further lowering of filling head C moves filling valve  74  to an open position in which inlet openings  74   b  are in fluid communication with liquid  71  in container  70  (FIG.  7 ). The liquid is then delivered into the empty container until it is full. Air vent openings  74   c  are included in valve  74  for venting and relieving air from container  26  during filling. As soon as all the air is vented from the bottle, the filling operation stops. Container  70  includes a valve bracket  76  having a button  76   a . A spring  78  is carried on button  76   a  and a button  74   d  on valve  74  to extend therebetween and bias filler valve  74  downwardly. The illustrated filler tube and filling valve arrangement is suitable mainly for non-carbonated beverages, such as water, fruit and vegetable juices. Any suitable filling head valve and arrangement may be utilized for the beverages such as are available from several commercial sources such as U.S. Bottlers Company, Inc of Charlotte, N.C. It will be understood, of course, that other valve arrangements may also be utilized for non-carbonated and carbonated beverages such as beer and soft drinks, in accordance with the present invention. 
     It is noted that filling head reservoir  70  includes a curved bearing block  80  on opposing sides of the container. Bearing blocks  80  are received on parallel ledges  82  of support tray  56  so that the entire filling head C may rotate on the support tray as well as slide linearly. It is this combination of rotation and linear motion that allows the motion converter assembly to convert the circular motion of the filling heads to a straight line motion. 
     Referring to  FIGS. 5 ,  8 - 10 , filling-head motion converter F for controlling the processing heads in an articulating manner, will now be described in more detail. As noted above, each filling head C is slidably carried in support frame  56 , and there is defined a swivel axis  84  for the filling head as supported by tray  56  (FIG.  9 ). In this manner, filling heads C rotate about single turret axis Y, as they are carried by turret B, and articulate about swivel axis  84  at the same time. The processing head are controlled in a resultant straight-line path  64  path during initial engagement with containers  26 , for example, at engagement station  28 . Motion converter assembly F includes a plurality of connector mechanisms, designated generally as  90 , connected between rotating turret B and a respective filling head C to control movement of a filling head so it moves in straight line or chordal path  64  along engagement station  28  to align accurately with a group  32  of containers. As can best be seen in  FIG. 10 , a connector mechanism  90  includes a first linkage arrangement  92  connected to one side of the filling head, and a second linkage arrangement  94  connected to an opposite side of the filling head. The linkage arrangements include rotary-motion transfer camshafts  92   a  and  94   a  carried vertically between top and bottom turret plates  20  and  22 . Upper arm links  92   b  and  94   b  are received about upper ends of the camshafts and are secured against rotation. In this manner, actuation of upper links  92   b  and  94   b  causes rotation of the camshafts. Lower arm links  92   c  and  94   c  are slidably carried on camshafts  92  and  94  respectively. Lower arm links  92   c  and  94   c  are affixed to opposing sides of filling head C. Cam followers  92   e  and  94   e  are carried by upper links  92   b  and  94   b , and follow a cam plate  96  which is affixed to the top of stationary column  10  (FIG.  9 ). The cam followers ride in a cam groove  98  and follow cam plate  96  to actuate lower arm links  92   c  and  94   c  to swivel the filling heads an effect the resulting straight-line motion at engagement station  28 . The incorporated patent application describes this in more detail. In this manner, reliable insertion of filling valves  74  into the containers is had. 
     The motion of the filling head can best be seen in  FIG. 9 , as filling head C is maintained parallel and straight as the filling head is lowered onto the group of containers. It is to be understood, of course, that other means for articulating the filling heads C to convert the movement of the filling head from a circular path to a straight line path for alignment with the group of containers may also be had rather than the illustrated mechanism. For example, use of position sensors in control to electronic gear motor may be had, or hydraulic control systems, as well as other mechanical arrangements. In addition, other forms of rotating turrets or carousels may be used to rotate the processing heads in a circle. For example, an overhead rotating turret or umbrella structure with radial arms and depending processing heads may be utilized. In this case, the radial path of the rotating turret and processing heads is the same. The processing heads are carried to articulate about a vertical axis circumscribing the same circle as the heads. The heads may be made to articulate and maintain a straight-line path at any number of operational zones along the circular path. It may also be possible to lift the containers from underneath for engagement with the processing heads rather than overhead, without departing from the advantageous aspects of the invention, although overhead is preferred. 
     As can best be seen in  FIGS. 2 and 3 , a capping station, designated generally as  100 , is disposed along a straight run of outfeed conveyor station  30   c . Capping station  100  may include a pair of conventional rotary cappers  104   b  and  104   c . A laner assembly designated generally as  102  is provided to divide the groups of filled containers into a pair of single file rows  106   a  and  106   b . Laner assembly  102  includes a plurality of lanes  102   a ,  102   b , and  102   c  in a conventional manner. The rotary cappers place caps on the filled containers so that rows  106   a  and  106   b  on the exit side of the capping station include capped, filled containers. Variations and other arrangements of cappers may be had at the capping station, as well as various arrangements of capping stations in order to facilitate capping of any number of rows of single file bottles that may be produced by the filling apparatus and method of the invention. 
     The operation of the filling apparatus and method of the invention will now be described. After engagement of a filling head C with a group  32  of containers  26 , the filling operation takes place substantially over a 180 degree arc from engagement station  28  to a release station  28   b . At engagement station  28  the filling heads are lowered onto the groups of containers along straight line path  64 . The containers, with filling valves engaged, are conveyed along an arcuate path, and the empty containers are filled with the liquid. At release station  28   b , the filling head is raised from a group of containers so that successive groups  32   a  of filled containers exit at release station  28   b . The groups of filled containers are then conveyed to capping station  100 . At the capping station, lane dividers for separate and arranging the containers in the group in a pair of parallel, single file rows  102   a  and  102   b . The rows are then passed through rotary cappers  104   b  and  104   c  which place caps on the filled containers  26   a . The filled containers are then transferred for packaging. It is to be understood, of course, that other arrangements may be had at a capping station where more than two rows of single file containers are provided with additional cappers, perhaps downstream, for faster processing. 
     Thus, it can be seen, that an advantageous construction can be had for a filling machine to fill containers using a continuous, circular motion apparatus and method comprising rotating filling heads circularly arranged on a turret and having an articulated connection by which the heads depart from a circular path and move in a straight line to engage groups of empty containers arranged in plural, parallel rows, rather than a single row as utilized in the prior art so that increased production and overall reliability is enhanced. In accordance with apparatus and method of the present invention, containers or articles may be processed at half the linear speed for better control of the process, while the output is increased by 50% or more. 
     While a preferred embodiment of the invention has been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.